CY8CKIT-037
PSoC® 4 Motor Control Evaluation Kit Guide
Doc. No. 001-92562 Rev. *C
Cypress Semiconductor
198 Champion Court
San Jose, CA 95134 USA
www.cypress.com
Copyrights
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 2
© Cypress Semiconductor Corporation, 2015-2018. This document is the property of Cypress Semiconductor
Corporation and its subsidiaries, including Spansion LLC (“Cypress”). This document, including any software or
firmware included or referenced in this document (“Software”), is owned by Cypress under the intellectual property laws
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CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 3
Contents
Safety Information .......................................................................................................................................................... 5
1. Introduction .......................................................................................................................................................... 6
1.1 Kit Contents ........................................................................................................................................................... 6
1.2 Getting Started ...................................................................................................................................................... 7
1.3 Additional Learning Resources .............................................................................................................................. 8
1.4 Technical Support .................................................................................................................................................. 9
1.5 Documentation Conventions ................................................................................................................................. 9
1.6 Acronyms .............................................................................................................................................................. 9
2. Software Installation ......................................................................................................................................... 10
2.1 Before You Begin ................................................................................................................................................ 10
2.2 Install Kit Software ............................................................................................................................................... 10
2.3 Uninstall Software ................................................................................................................................................ 13
3. Kit Operation ...................................................................................................................................................... 14
3.1 CY8CKIT-037 Evaluation Kit Overview ............................................................................................................... 14
3.2 Kit Operation and Configuration Guide ................................................................................................................ 15
3.2.1 DC Power Supply Connector .................................................................................................................. 15
3.2.2 Motor Winding Connectors ..................................................................................................................... 15
3.2.3 Hall Sensors Interface Connector ........................................................................................................... 16
3.2.4 Connectors to CY8CKIT-042 Board ........................................................................................................ 16
3.2.5 USB Connector ....................................................................................................................................... 17
4. Hardware ............................................................................................................................................................ 18
4.1 Block Diagram Overview ..................................................................................................................................... 18
4.2 Input Protection Circuit ........................................................................................................................................ 19
4.3 DC/DC Switching Regulator ................................................................................................................................ 19
4.4 MOSFET Dual H-Bridge and Dual H-Bridge PWM Drivers .................................................................................. 20
4.5 Phase Current Detecting and Processing Circuit ................................................................................................. 21
4.6 Hall Sensors and BEMF Sensing Circuit ............................................................................................................. 22
4.7 USB-to-UART Bridge Controller Circuit ............................................................................................................... 23
4.8 Connectors .......................................................................................................................................................... 23
4.9 Test Points........................................................................................................................................................... 24
5. Code Examples .................................................................................................................................................. 25
5.1 Using the Kit Code Examples .............................................................................................................................. 25
5.2 Configuration Jumpers for Different Motor Types ................................................................................................ 28
5.3 Sensored BLDC Motor Control Code Example.................................................................................................... 28
5.3.1 Sensored BLDC Background .................................................................................................................. 28
5.3.2 Sensored BLDC Motor Control Code Example Overview ....................................................................... 29
Contents
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 4
5.3.3 Control Schematic Overview .................................................................................................................. 30
5.3.4 Flow Chart .............................................................................................................................................. 31
5.3.5 Running the Sensored BLDC Motor Control Code Example .................................................................. 32
5.3.6 Adapting the Code Example to another Motor ........................................................................................ 35
5.4 Sensorless BLDC Motor Control Code Example ................................................................................................. 36
5.4.1 Sensorless BLDC Background ............................................................................................................... 36
5.4.2 Sensorless BLDC Motor Control Code Example Overview .................................................................... 36
5.4.3 Control Schematic Overview .................................................................................................................. 37
5.4.4 Firmware Introduction ............................................................................................................................. 38
5.4.5 Running the Sensorless BLDC Motor Control Code Example ................................................................ 39
5.4.6 Adapting the Code Example to another Motor ........................................................................................ 42
5.5 Sensorless FOC Motor Control Code Example ................................................................................................... 49
5.5.1 Sensorless FOC Background ................................................................................................................. 49
5.5.2 Sensorless FOC Motor Control Code Example Overview ...................................................................... 55
5.5.3 Control Schematic Overview .................................................................................................................. 56
5.5.4 Firmware Introduction ............................................................................................................................. 58
5.5.5 Running the Sensorless FOC Motor Control Code Example .................................................................. 60
5.5.6 Adapting the Code Example to another Motor ........................................................................................ 62
5.6 Single Shunt FOC Motor Control Code Example ................................................................................................. 63
5.6.1 Single Shunt FOC Background ............................................................................................................... 63
5.6.2 Single Shunt FOC Motor Control Code Example Overview .................................................................... 65
5.6.3 Control Schematic Overview .................................................................................................................. 66
5.6.4 Firmware Introduction ............................................................................................................................. 67
5.6.5 Running the Single Shunt FOC Motor Control Code Example ............................................................... 68
5.6.6 Adapting the Code Example to another Motor ........................................................................................ 69
5.7 Stepper Motor Control Code Example ................................................................................................................. 70
5.7.1 Stepper Motor Background ..................................................................................................................... 70
5.7.2 Stepper Motor Control Code Example Overview .................................................................................... 71
5.7.3 Control Schematic Overview .................................................................................................................. 72
5.7.4 Firmware Introduction ............................................................................................................................. 73
5.7.5 Running the Stepper Motor Control Code Example ................................................................................ 74
5.7.6 Adapting the Code Example to another Motor ........................................................................................ 77
5.8 Bridge Control Panel Monitor Tool Guide ............................................................................................................ 78
5.8.1 BCP Monitoring Overview ....................................................................................................................... 78
5.8.2 Installing the Driver for CY7C65213 USB-to-UART Bridge Controller .................................................... 78
5.8.3 Upper Terminal Configuration Guide ...................................................................................................... 80
5.8.4 Lower Terminal Configuration Guide ...................................................................................................... 84
5.8.5 Reading the Motor Speed Using BCP Commands ................................................................................. 85
A.1. Board Schematics, Board Layout, and BOM ....................................................................................................... 87
A.2. Bill of Materials .................................................................................................................................................... 96
A.3. No Load Components .......................................................................................................................................... 99
A.4. Special Installation Instructions ......................................................................................................................... 100
A.5. Label .................................................................................................................................................................. 100
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 5
Safety Information
Regulatory Compliance
The CY8CKIT-037 PSoC
®
4 Motor Control Evaluation Kit is intended for use as a motor control development platform for
hardware or software in a laboratory environment. The board is an open-system design, which does not include a shielded
enclosure. Therefore, the board may cause interference with other electrical or electronic devices in close proximity. In a
domestic environment, this product may cause radio interference. In such cases, the user may be required to take adequate
preventive measures. Also, this board should not be used near any medical equipment or RF devices.
Attaching additional wiring to this product or modifying the product operation from the factory default may affect its
performance and cause interference with other apparatus in the immediate vicinity. If such interference is detected, suitable
mitigating measures should be taken.
The CY8CKIT-037, as shipped from the factory, has been verified to meet with the requirements of CE as a Class A
product.
The CY8CKIT-037 contains ESD-sensitive devices. Electrostatic charges readily accumulate on
the human body and any equipment, and can discharge without detection. Permanent damage
may occur to devices subjected to high-energy discharges. Proper ESD precautions are
recommended to avoid performance degradation or loss of functionality. Store unused CY8CKIT037 boards in the protective shipping package.
End-of-Life/Product Recycling
The end of life for this kit is five years from the date of manufacture mentioned on the back of the
box. Contact your nearest recycler to discard the kit.
General Safety Instructions
ESD Protection
ESD can damage boards and associated components. Cypress recommends that the user perform procedures only at an
ESD workstation. If an ESD workstation is not available, use appropriate ESD protection by wearing an antistatic wrist strap
attached to the chassis ground (any unpainted metal surface) on the board when handling parts.
Handling Boards
CY8CKIT-037 boards are sensitive to ESD. Hold the board only by its edges. After removing the board from its box, place it
on a grounded, static-free surface. Use a conductive foam pad if available. Do not slide the board over any surface.
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 6
1. Introduction
Thanks for your interest in the CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit (EVK). This kit enables engineers to
evaluate Cypress’ PSoC 4 family of devices for motor control applications. Based on this kit, customers can create control
solutions for three major motor types: Permanent Magnet Synchronous Motor (PMSM), stepper, and Brushless DC (BLDC).
The Cypress PSoC family of devices integrates abundant internal resources for motor control applications, such as Timer
Counter Pulse Width Modulator (TCPWM), SAR ADC, comparators, opamps, and universal digital blocks (UDBs). In
addition, an Arm® Cortex® core enables high-performance motor control solutions on PSoC devices. Headers provided on
the EVK board allow you to connect it to the CY8CKIT-042 PSoC 4 Pioneer Kit board to create a complete motor control
system.
This kit guide provides the circuit structure of the Motor Control EVK board and explains how to configure it to create a
solution for different motor types. It provides five code examples that cover sensored and sensorless BLDC control, PMSM
sensorless field-oriented control (FOC), and stepper motor microstepping control. It also introduces the Bridge Control
Panel (BCP) as a debugging tool in the motor control development process.
1.1 Kit Contents
The CY8CKIT-037 PSoC 4 Motor Control EVK includes the following:
• CY8CKIT-037 Motor Control Evaluation Board
• 24-V/2.1-A AC-DC Adapter
• BLDC motor (BLY172S-24V-4000) with sinusoidal back electromotive force
• USB Standard-A to Mini-B cable
• Configuration Jumpers
• Fuse
• Screwdriver
• Quick Start Guide
Introduction
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 7
Figure 1-1. CY8CKIT-037 PSoC 4 Motor Control EVK Contents
Inspect the contents of the kit. If you find any part missing, contact your nearest Cypress sales office for assistance:
www.cypress.com/support.
1.2 Getting Started
To learn the solution quickly and apply it to your design, refer to the CY8CKIT-037 PSoC 4 Motor Control Evaluation Kit
Quick Start Guide inside the kit box or in the installation directory. The default location for the kit documents is:
<Install_Directory>\CY8CKIT-037 Motor Control EVK\<version>\Documentation
This guide will help you get acquainted with the CY8CKIT-037 PSoC 4 Motor Control EVK:
The Introduction chapter describes the basic information of the CY8CKIT-037 PSoC 4 Motor Control Evaluation Kit.
The Software Installation chapter describes the installation of the kit software.
The Kit Operation chapter describes the major features of the CY8CKIT-037 PSoC 4 Motor Control Evaluation Kit.
The Hardware chapter describes the hardware content of the CY8CKIT-037 PSoC 4 Motor Control Evaluation Kit and
the hardware operation.
The Code Examples chapter describes the multiple projects that will help you understand how to evaluate different
supported output standards on this kit.
The Appendix captures DC/AC Measurements of Clock Outputs, Schematics, Fab Drawing, and the bill of materials
(BOM).
Introduction
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 8
1.3 Additional Learning Resources
Cypress provides a wealth of data at www.cypress.com to help you select the right PSoC device for your design, and to
help you to quickly and effectively integrate the device into your design. For a comprehensive list of resources, see
KBA86521, How to Design with PSoC 3, PSoC 4, and PSoC 5LP. The following is an abbreviated list for PSoC 4:
Overview: PSoC Portfolio and PSoC Roadmap.
Product Selectors: PSoC 4 Product Selector. In addition, PSoC Creator includes a device selection tool.
Datasheets: Describe and provide electrical specifications for the PSoC 4000, PSoC 4100, PSoC 4200, PSoC 4100M,
PSoC 4200M, and PSoC 4200L device families.
CapSense Design Guide: Learn how to design capacitive touch-sensing applications with the PSoC 4 family of devices.
Application Notes and Code Examples: Cover a broad range of topics, from basic to advanced. Many of the application
notes include code examples. Visit the PSoC 3/4/5 Code Examples webpage for a list of all available PSoC Creator
code examples.
Technical Reference Manuals (TRM): Provide detailed descriptions of the architecture and registers in each PSoC 4
device family.
Development Kits:
CY8CKIT-046, CY8CKIT-044, CY8CKIT-042, and CY8CKIT-040 are easy-to-use and inexpensive development
platforms. These kits include connectors for Arduino-compatible shields and Digilent Pmod peripheral modules.
CY8CKIT-049 and CY8CKIT-043 are low-cost prototyping platforms for sampling PSoC 4 devices.
MiniProg3 device provides an interface for flash programming and debug.
Knowledge Base Articles (KBA): Provide design and application tips from experts on using the device.
PSoC Creator Training: Visit www.cypress.com/go/creatorstart/creatortraining for a comprehensive list of video
trainings on PSoC Creator.
Learning from Peers: Visit www.cypress.com/forums to meet enthusiastic PSoC developers discussing the next generation
embedded systems on Cypress Developer Community Forums
Introduction
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 9
1.4 Technical Support
For assistance, go to www.cypress.com/support, or contact our customer support at +1(800) 541-4736 Ext. 3 (in the USA),
or +1 (408) 943-2600 Ext. 3 (International).
1.5 Documentation Conventions
Table 1-1. Document Conventions for Guides
Convention
Usage
Courier New
Displays file locations, user-entered text, and source code:
C:\...cd\icc\
Italics
Displays file names and reference documentation:
Read about the sourcefile.hex file in the PSoC Designer User Guide.
[Bracketed, Bold]
Displays keyboard commands in procedures:
[Enter] or [Ctrl] [C]
File > Open
Represents menu paths:
File > Open > New Project
Bold
Displays commands, menu paths, and icon names in procedures:
Click the File icon and then click Open.
Times New Roman
Displays an equation:
2 + 2 = 4
Text in gray boxes
Describes cautions or unique functionality of the product.
1.6 Acronyms
Table 1-2. List of Acronyms used in this Document
Acronym
Definition
BCP
Bridge Control Panel
BEMF
Back Electromotive Force
BLDC
Brushless DC
BOM
Bill of Materials
EVK
Evaluation Kit
FOC
Field-Oriented Control
IDE
Integrated Design Environment
IPMSM
Interior Permanent Magnet Synchronous Motor
ISR
Interrupt Service Routine
PMSM
Permanent Magnet Synchronous Motor
SPMSM
Surface Permanent Magnet Synchronous Motor
SVPWM
Space Vector Pulse Width Modulation
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 10
2. Software Installation
This chapter describes the steps to install the software tools and packages on a PC for using the CY8CKIT-037 PSoC 4
Motor Control EVK.
2.1 Before You Begin
All Cypress software installations require administrator privileges, but these are not required to run the software after it is
installed. Close any other Cypress software that is currently running before installing the kit software.
2.2 Install Kit Software
Follow these steps to install the CY8CKIT-037 PSoC 4 Motor Control EVK software:
1. Download the CY8CKIT-037 EVK software from www.cypress.com/CY8CKIT-037. The CY8CKIT-037 software is
available in the following formats for download (see Figure 2-1):
a. CY8CKIT-037 DVD ISO: This file is a complete package, stored in a CD/DVD-ROM image format that you can
use to create a CD/DVD or extract using an ISO extraction program such as WinZip or WinRAR. The file can
also be mounted similar to a virtual CD/DVD using virtual drive programs such as Virtual CloneDrive and
MagicISO. This file includes all the required software, utilities, drivers, hardware files, and user documents.
b. CY8CKIT-037 Evaluation Kit Complete Setup: This installation package contains the files related to the
CY8CKIT-037 Evaluation Kit. However, it does not include the Windows Installer or Microsoft .NET
Framework packages. If these packages are not available on your computer, the installer directs you to
download and install them from the Internet.
c. CY8CKIT-037 Evaluation Kit Only: This executable file installs only the CY8CKIT-037 EVK contents, which
include code examples, hardware files, and user documents. This package can be used if all the software
prerequisites (listed in step 4) are installed on your PC.
Figure 2-1. Available Formats for Downloading EVK Software
2. If you have downloaded the ISO file, mount it on a virtual drive. If you do not have a virtual drive to mount, extract
the ISO contents using the appropriate ISO extractor (such as MagicISO or PowerISO). Double-click
cyautorun.exe in the root directory of the extracted content or the mounted ISO if the “Autorun from CD/DVD”
option is not enabled on the PC. The installation window will appear automatically (see Figure 2-2).
Note: If you are using the “CY8CKIT-037 Kit Setup” or “CY8CKIT-037 Kit Only” file, then go to step 3 for
installation.
(a)
(b)
(c)
Software Installation
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 11
3. Click Install CY8CKIT-037 EVK to start the kit installation, as shown in Figure 2-2.
Figure 2-2. Kit Installer Startup Screen
4. Select the folder where you want to install the files related to the CY8CKIT-037 PSoC 4 Motor Control EVK.
Choose the directory and click Next.
Note: When you click the Next button, the CY8CKIT-037 installer automatically installs the required software, if it
is not present on your computer.
Following are the required software:
a. PSoC Creator 4.2 or later: This software is also available at www.cypress.com/psoccreator.
b. PSoC Programmer 3.27.1 or later: This is installed as part of PSoC Creator installation
(www.cypress.com/programmer).
Software Installation
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 12
5. Choose the Typical, Custom, or Complete installation type (select 'Typical' if you do not know which one to
select) in the Product Installation Overview window, as shown in Figure 2-3. Click Next after you select the
installation type.
Figure 2-3. Product Installation Overview Window
6. Read the License agreement and select I accept the terms in the license agreement to continue with the
installation. Click Next.
7. When the installation begins, a list of packages appears on the installation page. A green check mark appears next
to each package after successful installation.
8. Enter your contact information or select the option Continue without Contact Information. Click Finish to
complete the CY8CKIT-037 kit installation.
9. After the installation is complete, the kit contents are available at the following location:
<Install_Directory>\CY8CKIT-037 Motor Control EVK.
Default location:
a. Windows OS (64-bit):
C:\Program Files(x86)\Cypress\CY8CKIT-037 Motor Control EVK
b. Windows OS (32-bit):
C:\Program Files\Cypress\CY8CKIT-037 Motor Control EVK
Note: For Windows 7/8/8.1/10 users, the installed files and the folder are read-only.
To use the installed code examples, follow the steps outlined in Using the Kit Code Examples section. These steps
will create an editable copy of the example in a path that you choose so the original installed example is not
modified.
Software Installation
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 13
2.3 Uninstall Software
The software can be uninstalled using one of the following methods:
• Go to Start > Control Panel > Programs and Features for Windows 7 or Add/Remove Programs for Windows
XP and select the Uninstall button.
• Go to Start > All Programs > Cypress > Cypress Update Manager and select the Uninstall button next to the
product that needs to be uninstalled.
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3. Kit Operation
This chapter introduces you to the features of the CY8CKIT-037 EVK. It describes the connectors of the board and
the usage of these connectors.
3.1 CY8CKIT-037 Evaluation Kit Overview
The motor control system can be separated into two parts: the driver board and the controller board. The CY8CKIT-037
Motor Control EVK is the driver board, which contains the DC/DC power circuit, dual H-bridge circuit, motor current and bus
voltage sampling and processing circuit, protection circuit, user configuration circuit, and connectors to the controller board.
The controller board receives the signals, implements the proper algorithm to process them, and then generates control
signals to the driver board to run the motor. Figure 3-1 shows the EVK board and its general description. CY8CKIT-037
EVK is the driver board; the CY8CKIT-042 kit works as the controller board. They are interfaced with Arduino-compatible
connectors.
Figure 3-1. General Description of EVK Board
Kit Operation
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 15
3.2 Kit Operation and Configuration Guide
3.2.1 DC Power Supply Connector
There are two connectors for DC power input, J7 and J8, as shown in Figure 3-2. J7 is a standard power jack for DC
adapters with 12 V or 24 V DC output. J8 enables the kit to get input power from a general variable DC power supply with
24 V to 48 V DC output voltage. The input current of both connectors can be up to 2 A. For schematic details, see Input
Protection Circuit. CY8CKIT-042 gets 12 V from the DC/DC converter on CY8CKIT-037. The LDO on CY8CKIT-042
generates the 3.3 V supply for the PSoC device if the VDD on CY8CKIT-042 is configured as 3.3 V. If the VDD on
CY8CKIT-042 is configured as 5 V, CY8CKIT-042 needs 5 V from the USB cable.
CAUTION
Do not connect power to both J7 and J8 simultaneously. Also, when using J7, connect the power
cable to it before loading the AC supply at the AC/DC adapter to avoid a potential spark.
Figure 3-2. Connectors for DC Power Input
3.2.2 Motor Winding Connectors
J9 and J10 provide four pins for motor windings, as shown in Figure 3-3. The BLDC and PMSM motors use three pins,
while the stepper motor application needs all four pins.
Connection details are as follows:
For BLDC and PMSM:
• Pin 1–1A (A) Motor winding A – Red
• Pin 2–2A (B) Motor winding B – Yellow
• Pin 3–1B (C) Motor winding C – Black
For stepper motor:
• Pin 1–1A (A) Motor winding 1 terminal A – Blue
• Pin 2–2A (B) Motor winding 1 terminal B – Yellow
• Pin 3–1B (C) Motor winding 2 terminal A – Red
• Pin 4–2B Motor winding 2 terminal B – Green
For schematic details, see Connectors.
Figure 3-3. Connectors to Motor Windings
J7
J8
J10
J9
Kit Operation
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 16
3.2.3 Hall Sensors Interface Connector
J12 is the Hall Sensors Interface Connector for the Sensored BLDC Motor Control code example, as Figure 3-4 shows. It is
a five-pin connector.
The details of each pin are as follows:
• VDD: Hall sensor board VDD – Red
• HALLA: Hall sensor A output – Blue
• HALLB: Hall sensor B output – Green
• HALLC: Hall sensor C output – White
• GND: Hall sensor board ground – Black
For schematic details, refer to Hall Sensors and BEMF Sensing Circuit.
Figure 3-4. Hall Sensors Connector
3.2.4 Connectors to CY8CKIT-042 Board
Figure 3-5 shows the Arduino-compatible connectors to the CY8CKIT-042 board: J1, J2, J3, and J4. You can plug the EVK
board into the CY8CKIT-042 board through these connectors. For schematic details, refer to Connectors.
Note: Pin connectors J1, J2, J3, and J4 may bend when plugging the EVK board into CY8CKIT-042.
Figure 3-5. Connectors to CY8CKIT-042 Board
J12
J3
J4
J1
J2
Kit Operation
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 17
3.2.5 USB Connector
To monitor the real-time parameters while the motor is running, you can use the Bridge Control Panel (BCP) (refer to Bridge
Control Panel Monitor Tool Guide) to get data through the USB-to-UART bridge circuit on the EVK board during the
debugging process. The USB-to-UART bridge circuit on the EVK board can be connected to the PC using a USB Cable
connected at the J11 connector, as shown in Figure 3-6. For schematic details of the USB-to-UART bridge circuit part, refer
to USB-to-UART Bridge Controller Circuit.
Figure 3-6. USB-to-UART Bridge Controller Circuit
J11
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 18
4. Hardware
4.1 Block Diagram Overview
Figure 4-1 illustrates the CY8CKIT-037 hardware block diagram. The major features are as follows:
• Input protection circuit
• DC/DC switching regulator
• MOSFET dual H-bridge and dual H-bridge PWM drivers
• Phase current detecting and processing circuit
• Hall and back electromagnetic force (BEMF) sensing circuit
• USB-to-UART bridge controller circuit
• Connectors
• Test points and LEDs
Figure 4-1. CY8CKIT-037 Hardware Block Diagram
Hardware
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 19
4.2 Input Protection Circuit
Figure 4-2 shows the input protection circuit that consists of three parts: overcurrent protection by fuse F1 or F2, power
supply reverse protection by Schottky diode D2, and input voltage inrush protection by varistor VR1. Notice that there are
two parallel fuses: F1 is a PTC resettable fuse, and F2 is a common thermal fuse. F2 is populated onboard by default. You
can also use PTC fuse F1 to replace F2 according to your requirements.
Figure 4-2. Input Protection Circuit
CAUTION
Do not populate both F1 and F2 on the EVK board. Otherwise, when an overcurrent condition
occurs, F1 and F2 cannot cut off the circuit, which will lead to component damage on the board.
4.3 DC/DC Switching Regulator
Figure 4-3 shows the DC/DC switching regulator circuit on the EVK board. It converts the voltage V
in
(output of the input
protection circuit, 0.5 V to 1 V lower than the input voltage) to +12 V.This switching converter is a buck regulator using
LM5005. LM5005 has an internal 75 V N-channel buck switch with an output current capability of 2.5 A. It is designed to
take an input in the range of 7 V–75 V and provides 12 V output with 1.5 A current capability when the input voltage is
higher than 13 V.
Figure 4-3. Switching DC/DC Converter
When the voltage at the SD pin of LM5005 is less than 1.225 V, the IC will go into an inactive state. The external R1 and R2
divider with 10 kΩ and 2 kΩ will give exactly 1.225 V at 7.35 V input. If the input goes below 7.35 V, LM5005 will be in an
inactive state.
The +12 V output of the regulator provides power to the dual H-bridge driver chips and the PSoC 4 Pioneer Kit. The power
supply in the range of 2.7 V to 5.5 V, needed by the other circuits and chips on the EVK board is provided from the
controller board through the Arduino headers.
Hardware
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 20
4.4 MOSFET Dual H-Bridge and Dual H-Bridge PWM Drivers
This part (see Figure 4-4) contains four half-bridge circuits and four driver circuits. For BLDC and PMSM control, you can
use three half-bridge circuits to form a standard three-phase inverter. For the stepper motor, you can control two windings
of the stepper motor separately via the dual H-bridge.
Figure 4-4 shows the driver circuit, containing four ASIC driver chips (IR2101) and relative peripheral components. IR2101
can source 100 mA or sink 210 mA current to the MOSFETs. Each chip can drive two MOSFETs of a half-bridge, and its
high-side PWM operates with a floating supply by a peripheral bootstrap circuit.
Figure 4-4. Dual H-Bridge Driver Circuit
Figure 4-5 shows the MOSFET dual H-bridge. There are four half bridges in total, each one serving a motor phase or
winding. Considering the compatibility for different motor control types, the population of components J19, J20, and J21
needs to be adjusted to fit different motor type applications.
Figure 4-5. MOSFET Dual H-Bridge
Hardware
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 21
4.5 Phase Current Detecting and Processing Circuit
As Figure 4-5 shows, three sensing resistors (R34, R35 and R36) are inserted into three half-bridges. When the motor is
running, the winding current floats through these resistors. So, detecting the voltage on the sensing resistors can get the
phase current of the motor windings. Because of the sensing resistors’ low value and the noise of the running motor, the
voltage signal needs to be amplified. Figure 4-6 shows the current detecting and processing circuit for winding A and
winding C.
The core of this circuit is the amplifier. The internal opamps of the PSoC 4 on the controller board are used. J18 and J23
are used only for PMSM FOC control because in the FOC application, the winding current can be both positive and
negative. J18 and J23 add 1/2 VDD bias voltage to the sensing signal to make it always positive.
J22 is used only for the sensorless BLDC application, because the sensorless BLDC firmware uses an inside low-power
comparator (LPComp). P1[1] is dedicated to the negative terminal of the comparator, which needs to be connected to the
Vin divider circuit (P2[6]/Vin). R49 will change the divider proportion. Pins 2 and pin 3 of J22 need to be shorted to remove
R49 from the circuit in the Sensorless BLDC Motor Control code example.
Figure 4-6. Current Detecting and Processing Circuit
Figure 4-7 shows the external two-phase winding current comparing circuit, which is used only in the stepper motor
application. The positive terminal input is the current sensing signal after amplifying and filtering, and the negative terminal
input is the current reference set by the internal IDAC. The comparator output is routed to the PWM kill terminal to shut
down the PWM output, forcing the winding current to follow the IDAC current reference.
Figure 4-7. Two-Phase Winding Current Comparing Circuit
(Winding A)
(Winding C)
Hardware
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 22
Figure 4-8 shows the overcurrent protection circuit. R60, R61, and R62 add the three-phase winding current, and the
external opamp U7 amplifies and filters the sum of the currents. Its output is routed to the positive terminal of the internal
comparator to be compared with the overcurrent threshold set by the IDAC.
Figure 4-8. Overcurrent Protection Circuit
4.6 Hall Sensors and BEMF Sensing Circuit
Both sensored and sensorless BLDC motors can be rotated with the EVK board. The sensored BLDC gets its rotor position
from the Hall sensors, and the sensorless BLDC gets its rotor position by detecting the BEMF signal from the stator
winding. Figure 4-9 shows the Hall sensor interface. The Hall sensor output is in an open-collector structure, so the
interface adds pull-up resistors to make the PSoC device receive the correct Hall sensor signal.
Figure 4-9. Hall Sensor Interface
Figure 4-10 shows the voltage divider and filter circuit for BEMF detection. Three phases of the Hall sensor and BEMF
signals are routed to jumpers J13, J14, and J15, as shown in Figure 4-11. Users can select sensored or sensorless
configuration via the three jumpers.
Figure 4-10. Sensorless BLDC BEMF Detecting Circuit
Hardware
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 23
Figure 4-11 shows that the two Hall sensor and BEMF signals, as well as the two external comparator output kill signals of
the stepper motor, are routed to J16 and J17. Since the GPIO pin numbers of PSoC 4 are limited, these signals need to
share two GPIO pins. Be sure to configure J16 and J17 correctly for the BLDC and stepper motor applications.
Figure 4-11. Signal Configuration Jumpers
4.7 USB-to-UART Bridge Controller Circuit
Figure 4-12 shows the USB-to-UART bridge controller used for transferring data, such as speed and winding current, that
you want to monitor on the BCP. The bridge controller receives the data from PSoC 4 on CY8CKIT-042 over UART and
transmits it over USB to be monitored using the BCP software.
Figure 4-12. USB-to-UART Bridge Controller
4.8 Connectors
There are several connectors on the EVK board. Figure 4-13 shows the input power connectors. J7 is the standard power
jack for DC adapters, with an output from 12 V to 24 V. J8 can accept an input voltage from 24 V to 48 V through raw wire
from a general variable DC power supply. The input current of both connectors can be as high as 2 A.
Figure 4-13. Input Power Supply Connectors
Hardware
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 24
Figure 4-14 shows the motor winding connectors. The two connectors provide four pins in total. The BLDC motor contains
three windings with a common neutral point inside the motor. It uses only three pins. The stepper motor contains two
independent windings, so it needs all four pins.
Figure 4-14. Motor Winding Connectors
Figure 4-15 shows the connectors to the CY8CKIT-042 board. The layout of connectors J1, J2, J3, and J4 on the EVK
board is designed to be pin-to-pin compatible with J1, J2, J3, and J4 on the Pioneer Kit, so users can plug the EVK board
directly into the Pioneer Kit.
Figure 4-15. Connectors to CY8CKIT-042
4.9 Test Points
The EVK board provides many test points of critical signals, making it convenient for users to debug during the
development process. Test points cover driver PWMs, power output and ground, winding current, and IDAC reference
output. You can observe and monitor these signals using probes. Figure 4-16 shows some instances of test points.
Figure 4-16. Test Points
CAUTION
Do not power the kit through these test points to avoid damage to the board.
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 25
5. Code Examples
The CY8CKIT-037 EVK can be evaluated using code examples, which can help you accelerate the motor control
development processes that configure the device with PSoC 4.
5.1 Using the Kit Code Examples
Follow the steps below to use the installed code examples.
1. Launch PSoC Creator from Start > All Programs > Cypress > PSoC Creator<version> > PSoC Creator <version>.
2. On the Start page, click CY8CKIT-037 Motor Control EVK under Start > Kits. The code examples shipped with
the kit appear (see Figure 5-1).
Figure 5-1. Product Installation Overview Window
3. Click on the desired code example, select a location to save the example and click OK.
4. Build the code example by choosing Build > Build <Project_Name>. After the build process is successful, a .hex
file is generated.
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 26
5. To program, connect the PSoC 4 Pioneer Kit to the computer using the USB cable connected to port J10.
Figure 5-2. Connect USB Cable to J10
6. Choose Debug > Program in PSoC Creator.
7. If the device is yet to be acquired, the Select Debug Target window will appear. Select KitProg/<serial_number>
and click Port Acquire, as shown in Figure 5-3.
Figure 5-3. Acquire Device from PSoC Creator
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 27
8. After the device is acquired, it is shown in a tree structure below the KitProg/<serial_number>. Now, click the
Connect button.
Figure 5-4. Connect Device from PSoC Creator
9. Click OK to exit the window and start programming.
Figure 5-5. Program Device from PSoC Creator
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 28
5.2 Configuration Jumpers for Different Motor Types
CY8CKIT-037 supports three motor types: BLDC, PMSM, and stepper. When switching between different motor types or
algorithms, the EVK board needs to be reconfigured via jumpers J13–J24. The jumper configuration table is printed on the
top layer of the EVK board, as shown in Figure 5-6.
Figure 5-6. J13–J24 Configuration Table for Different Motors
These jumpers are located in several different circuit parts. To learn about the principle of configuration, refer to Hardware.
Note: When you prepare to change the configuration jumper settings for different motor types, ensure that all power
sources are turned off; otherwise, the kits may be damaged.
5.3 Sensored BLDC Motor Control Code Example
5.3.1 Sensored BLDC Background
BLDC motors are widely used in industrial applications, home appliances, and vehicle systems. Such motors consist of a
multi-pole permanent magnet placed on the rotor and several windings. In the BLDC motor, the commutation is controlled
electronically. The motor requires the stator windings to be energized in a particular sequence. To implement this
sequence, it is important to know the rotor position. The simplest way is to use rotor position sensors. The sensors can be
optical, magnetic (Hall or magneto-resistance effect based), or inductive. The Hall sensor is selected in most applications
for its high accuracy and low cost.
Hall sensors are embedded in the stator. When the rotor magnetic poles pass near the Hall sensors, they supply a high or
low signal, indicating that the north or south poles are passing nearby. The rotor position is derived from the exact
combination of the three Hall sensor signals. Three position sensors can provide six effective states (except 000 and 111)
and separate a whole electrical space into six parts, each having a 60-degree electrical angle. Figure 5-7 gives a timing
diagram of the sensor output and the required motor driving voltage. The optional use of a PWM provides speed or torque
control as shown in phases U, V, and W. The duty cycle of the modulated output control signal (PWM) is varied to change
the speed and torque of the motor.
Figure 5-7. BLDC Sensor Output Versus Commutation Timing
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 29
5.3.2 Sensored BLDC Motor Control Code Example Overview
Figure 5-8 illustrates the block diagram of the Sensored BLDC Motor Control code example based on PSoC 4.
Figure 5-8. Block Diagram of Sensored BLDC Motor Control Code Example based on PSoC 4
GPIO
SAR
ADC
State Machine
( Speed Control
& Commute )
PWM
Generator
OP
IDAC
CMP
GPIO
GPIO
GPIO
PSoC 4
BLDC
Motor
Inverter
12V & 5V
Power Supply
24V Power
Supply
/ 6
/3
/3
Speed
Command
Bus Voltage
Bus Current
Hall Sensors
The input control signals to the PSoC 4 device are as follows:
• Speed command: Analog input pin that measures the voltage across a potentiometer to set the desired speed of
rotation (one analog input pin).
• Motor current detection: Analog input pin that detects and cuts off the power device driver to protect the motor
when an overcurrent condition is detected (see Error! Reference source not found.) (one analog input pin).
• Hall sensors: Three digital input pins connected to the outputs of the Hall sensors from the motor. These sensor
inputs provide the position of the motor and are used to control the commutation by varying the PWM output
signals to the power driver (three digital input pins).
• Start/stop control: Digital input connected to a switch to start and stop motor rotation (one digital input pin).
Outputs from the PSoC 4 device are power device driver signals.
• PWM signals to the high side of the MOSFET driver (three digital output pins)
• PWM signals to the low side of the MOSFET driver (three digital output pins)
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 30
5.3.3 Control Schematic Overview
The Sensored BLDC Motor Control code example firmware is developed in PSoC Creator 4.2. Its schematic is separated
into two pages according to their function. Figure 5-9 shows the “PWM Drive and Commutate” schematic. The three Hall
sensor signals are imported by pins “Hall1”, “Hall2”, and “Hall3”. The “LUT_Cmut” outputs the PWM signal to the motor
windings according to the Hall signals and its internal commutation table. “PWM_Drive” generates the real-time duty cycle
to follow the user’s RPM request.
Figure 5-9. PWM Drive and Commutate Schematic
Figure 5-10 shows the “ADC sampling” schematic. “ADC_SAR_Seq_1” is the SAR ADC to detect and measure the bus
voltage and potentiometer voltage.
Figure 5-10. ADC Sampling Schematic
Figure 5-11 shows the “Speed Measurement” schematic. “Counter_Spd” uses one Hall signal to measure the RPM of the
motor. It can work as real-time feedback of the closed-loop speed control.
Figure 5-11. Speed Measurement Schematic
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 31
Figure 5-12 shows the “Overcurrent Protection” schematic. The motor current is detected by the sensing resistor and
amplified by the external or internal opamp. The current signal is routed to the positive terminal of the internal low-power
comparator “LPComp_OC”. The negative terminal of the comparator is the overcurrent threshold set by the internal IDAC
“IDAC_Iref.” In an overcurrent condition, “LPComp_OC” will trigger an interrupt, and an overcurrent action will be executed
in its ISR.
Figure 5-12. Overcurrent Protection Schematic
5.3.4 Flow Chart
Figure 5-13 shows the flow chart of the main loop function. The project schematic in Figure 5-9 shows that hardware
performs the commutation. So, the firmware processes only the closed-loop speed control, button detecting, and protective
action.
Figure 5-13. Main Loop Function Flow Chart
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 32
5.3.5 Running the Sensored BLDC Motor Control Code Example
5.3.5.1 Step 1 – Configure CY8CKIT-042
Select 5V as the VDD power at jumper J9 on the Pioneer Kit, and always keep the USB cable connected to the Pioneer Kit
because the Pioneer Kit does not provide a 5 V converter. It gets 5 V power directly from the USB port of the PC.
Figure 5-14 shows the CY8CKIT-042 configuration.
Figure 5-14.CY8CKIT-042 Configuration for Sensored BLDC Motor Control Code Example
5.3.5.2 Step 2 – Configure CY8CKIT-037
Configure the board via jumpers J13–J24 for the Sensored BLDC Motor Control code example (“HALL SENSOR BLDC”
row in Figure 5-6). The CY8CKIT-037 is configured for sensored BLDC control by default. If you have not made any
changes since receiving it from Cypress, bypass this step and go to Step 3 – Plug CY8CKIT-037 into CY8CKIT-042.
Figure 5-15 shows the jumper overview after configuration.
Figure 5-15. Configuration for Sensored BLDC Motor Control Code Example
USB Cable
Select 5V
as VDD
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 33
5.3.5.3 Step 3 – Plug CY8CKIT-037 into CY8CKIT-042
Plug the EVK board into the Pioneer Kit via connectors J1–J4, as shown in Figure 5-16.
Figure 5-16. Plug CY8CKIT-037 EVK into CY8CKIT-042 Pioneer Kit
5.3.5.4 Step 4 – Connect the Power Supply and Motor
Connect the BLDC motor to the EVK board, including windings to J9/J10 and Hall sensor to J12. The wire sequence and
color for the motor windings and Hall sensor should be exactly as shown in Figure 5-17. Refer to Motor Winding Connectors
and Hall Sensors Interface Connector for instructions. Connect a 24 V power adapter to J7 on CY8CKIT-037. Connect a
USB cable to CY8CKIT-042 at connector J10; connect the other end of the USB cable to the PC. LED1 glows, indicating
that the kit is powered. If it is not glowing, the fuse F2 may be broken. Replace F2 with the backup fuse provided with the
kit.
Figure 5-17. Connect Motor and Power Supply
LED1
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 34
5.3.5.5 Step 5 – Build the Project and Program PSoC 4
Open the Sensored BLDC Motor Control code example in PSoC Creator 4.2 or later version, as shown in Figure 5-18.
Choose Build > Build Sensored BLDC Motor Control to start building the project, and then choose Debug > Program to
program the chip.
Figure 5-18. Open the Sensored BLDC Motor Control Code Example
CAUTION
During the debugging process, if you modify the code in the firmware, make sure that the
changes do not turn on both the high-side and low-side MOSFETs.
5.3.5.6 Step 6 – Press the SW2 Button to Start Motor Rotation
Ensure that the USB cable from the CY8CKIT-042 is connected to the PC in this step; otherwise, the motor will not rotate.
Press the SW2 button to start motor rotation (see Figure 5-19). Rotate the potentiometer clockwise to increase the motor
speed or vice versa. If the motor does not rotate and you observe LED2 blinking, it indicates that an error has occurred. If
so, ensure that step 1 through step 5 have been executed correctly. Then press the Reset button and press the SW2 button
again. If LED2 still blinks, there must be a problem in the hardware or software. Contact Cypress for technical support.
Figure 5-19. Buttons and Status LED
CAUTION
Do not remove jumpers while the kit is powered. This may damage the kit.
Reset
SW2
LED2
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 35
5.3.6 Adapting the Code Example to another Motor
This code example can be changed to rotate other sensored BLDC motors. Some parameters in the project firmware need
to be modified according to specific motor characteristics and functional requirements. These parameters are defined as a
struct in motor.h.
typedefstruct
{
uint8 Dir; /*Direction*/
uint16 speedRpm; /* Actural motor speed*/
uint16 speedRpmRef; /* motor speed command value*/
uint16 kp; /* Proportional coeffient of PID*/
uint16 ki; /* Integral coeffient of PID*/
uint16 maxSpeedRpm; /* Motor parameters*/
uint16 minSpeedRpm; /* Motor parameters*/
uint8 polePairs; /*POLE PAIRS*/
uint8 maxCurr; /*Over current threshold*/
}UI_DATA;
The struct variable is in motor.c and is initialized in motor.c by function Init_UI_FW.
UI_DATA UI_Data;
void Init_UI_FW(void)
{
/* Setting UI Initial parameter*/
UI_Data.Dir = CLOCK_WISE;
UI_Data.maxSpeedRpm = 4000;
UI_Data.minSpeedRpm = 500;
UI_Data.speedRpmRef = 1000;
UI_Data.polePairs = 4;
UI_Data.maxCurr = MAX_CURR_MEDIUM;
UI_Data.kp = 500;
UI_Data.ki = 50;
}
The Init_UI_FW function initializes the parameters before the motor begins rotating, and the initializing value is specific to
the motor shipped in the kit package. If you want to use your own motor and have different functional requirements such as
RPM or direction, change the initializing value in this function.
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 36
5.4 Sensorless BLDC Motor Control Code Example
5.4.1 Sensorless BLDC Background
Various methods can be employed to control the BLDC motor. The simplest way is to use Hall position sensors. However,
sensors increase cost and add reliability problems in motors operating in harsh environments where demands for sensor
robustness are high. The increasing power of embedded computing, coupled with lower prices for power semiconductors
and microcontrollers, has allowed more sophisticated methods of motor control. One popular technique is to use a BEMF
signal, which is induced by revolving the rotor permanent magnet around the drive coils.
Most BLDC motors have a three-phase winding topology with a star connection. It is driven by energizing two phases
simultaneously, while the other phase is kept afloat. The key to BLDC commutation is to sense the rotor position and then
energize the phases that produce the maximum amount of torque. The rotor travels 60 electrical degrees at every
commutation step. The appropriate stator current path is activated when the rotor is 120 degrees away from alignment with
the corresponding stator magnetic field. It is then deactivated when the rotor is 60 degrees from alignment. The next circuit
is activated and the process repeats.
Figure 5-20 shows that every commutation sequence has one winding energized positive, the second is negative, and the
third winding is left open. The voltage polarity of BEMF crosses from positive to negative or from negative to positive (zerocrossing) between two commutations. Ideally, the zero-crossing of BEMF occurs at 30 electrical degrees after the last
commutation and 30 electrical degrees prior to the next commutation. By measuring the zero-crossing of BEMF and the
30-degree time interval, the controller can perform the commutation without a position sensor.
Figure 5-20. General Operating Waveforms of Phase Voltages and Currents
5.4.2 Sensorless BLDC Motor Control Code Example Overview
Figure 5-21 illustrates the block diagram of the Sensorless BLDC Motor Control code example based on PSoC 4.The input
control signals to the PSoC 4 device are the following:
• Speed command: An analog input pin that measures the voltage across a potentiometer to set the desired speed
of rotation (one analog input pin).
• Motor current detection: An analog input pin to detect and cut off the power device driver to protect the motor
when an overcurrent condition is detected (see Control Schematic Overview) (one analog input pin).
• Half Vbus: An analog input pin that routes half-bus voltage to the negative terminal of the internal low-power
comparator.
• BEMF divider voltage: Three analog input pins connected to the outputs of the BEMF divider circuit. These
BEMF inputs are routed to the internal AMUX, which selects the proper BEMF signal sequentially to compare with
the half Vbus to get the zero-crossing point of the non-energized winding.
• Start/stop control: A digital input connected to a switch to start and stop rotation of the motor (one digital input
pin).
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 37
Outputs from PSoC 4 are power device driver signals.
• PWM signals to the high side of the MOSFET driver (three digital output pins)
• PWM signals to the low side of the MOSFET driver (three digital output pins)
Figure 5-21. Sensorless BLDC Motor Control Code Example Block Diagram
GPIO
SAR
ADC
State Machine
( Speed Control
& Commutate)
PWM
Generator
OP
IDAC
CMP
AMUX
CMP
GPIO
GPIO
GPIO
PSoC 4
BLDC
Motor
Inverter
12V & 5V
Power Supply
24V Power
Supply
/ 6
/3
/3
Speed
Command
Bus Voltage
Bus Current
BEMF Divider
Half Vbus
5.4.3 Control Schematic Overview
The Sensorless BLDC Motor Control code example firmware is developed in PSoC Creator 4.2. Its schematic is separated
into two pages according to their function. Figure 5-22 shows the “BEMF Checking” schematic. Three BEMF signals are
routed to the internal AMUX “AMux_1”. The AMUX selects a non-energized BEMF and compares it with the half Vbus. If
zero-crossing output happens, the internal low-power comparator “BEMF_Comp” toggles its output. The logic gating circuit
on the right side of “BEMF_Comp” generates a pulse when “BEMF_Comp” toggles its output so that PSoC 4 can get a
pulse at each zero-crossing point. The pulse triggers an interrupt, and the relevant code is executed in its ISR.
Figure 5-22. BEMF Checking Schematic
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 38
Figure 5-23 shows the “PWM Drive and Commutation” schematic. “SectorCtrl” indicates the current rotor position. It is
dynamically changed in the firmware by the zero-crossing detecting ISR. “LUT_1” outputs the PWM signal to the motor
windings according to the “SectorCtrl” output and its internal commutation table. “PWM_Drive” generates the right duty
cycle to follow the user’s RPM request. “Counter_Spd” is used to measure motor speed; it works as a real-time feedback of
the closed-loop speed control.
Figure 5-23. PWM Drive and Commutation Schematic
5.4.4 Firmware Introduction
The Sensorless BLDC Motor Control code example employs the typical three-step startup algorithm. The BEMF amplitude
of BLDC is proportional to the motor speed. If the motor stops, there is no BEMF. When the motor rotates at a low speed,
the BEMF is too weak to be detected. Therefore, before the BEMF can be measured by the firmware, there is a “freerunning” stage in which the BLDC motor rotates step by step to acquire the initial BEMF zero-crossing signal before running
sensorless control.
When rotating at a certain speed with open-loop stepping stimulation, the rotor position is approximately 90 electrical
degrees ahead of that when run correctly under sensorless control. As a result, the BEMF zero-crossings cannot be
sensed. To observe the zero-crossings, it is necessary to accelerate the motor at a certain rate.
In this stage, the PWM duty cycle increases gradually, and the commutating period is longer than usual. A ramp-up table in
the firmware defines the timeout of every commutating period. The value of the table content is a result of experiments
based on different motor types. When sufficient valid zero-crossing events are detected, the firmware enters the normal
synchronous running stage. If the firmware cannot detect sufficient valid zero-crossing events during a period of time, an
error occurs and the BLDC must stop and wait for the next round of the free-running stage. Figure 5-24 shows the starting
sequence.
Figure 5-24. Starting Sequence for Sensorless BLDC Motor
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 39
The main part of the sensorless startup and normal running control algorithm is in the PWM ISR. Figure 5-25 shows a flow
chart of the PWM ISR.
Figure 5-25. PWM ISR Flow Chart
5.4.5 Running the Sensorless BLDC Motor Control Code Example
Perform these steps to run the Sensorless BLDC Motor Control code example.
5.4.5.1 Step 1 – Configure CY8CKIT-042
1. Select 5V as the VDD power at jumper J9 on the Pioneer Kit. Ensure to keep the USB cable connected to the
Pioneer Kit because the Pioneer Kit does not provide a 5 V converter. It gets 5 V power directly from the USB port
of the PC. Figure 5-14 shows the configuration.
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 40
5.4.5.2 Step 2 – Configure CY8CKIT-037
1. Configure the board via jumpers J13–J24 for the Sensorless BLDC Motor Control code example (“SENSORLESS
BLDC” row in Figure 5-6). Figure 5-26 shows the EVK board configured for the Sensorless BLDC Motor Control
code example.
Figure 5-26. EVK Board Configuration for Sensorless BLDC Motor Control Code Example
5.4.5.3 Step 3 – Plug CY8CKIT-037 into CY8CKIT-042
1. Plug the EVK board into the Pioneer Kit via connectors J1–J4, as shown in Figure 5-16.
5.4.5.4 Step 4 – Connect the Power Supply and Motor
1. Connect the BLDC windings to J9 and J10 on the EVK board.
2. Connect the 24 V power adapter to J7, and connect a USB cable from J10 on CY8CKIT-042 to the PC, as shown
in Figure 5-27. LED1 glows, indicating that the kit is powered. If it is not glowing, the fuse F2 may be broken.
Replace F2 with the backup fuse provided with the kit.
Figure 5-27. Connect Motor and Power Supply
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 41
5.4.5.5 Step 5 – Build the Project and Program PSoC 4
1. Open the Sensorless BLDC Motor Control code example in PSoC Creator 4.2 or later version,
as shown in Figure 5-28.
2. Choose Build > Build Sensorless BLDC Motor Control to start building the project, and then
choose Debug > Program to program the chip.
Figure 5-28. Open the Sensorless BLDC Motor Control Code Example
CAUTION
During the debugging process, if you modify the code in the firmware, make sure that the
changes do not turn on both the high-side and low-side MOSFETs.
5.4.5.6 Step 6 – Press the SW2 Button to Start Motor Rotation
1. Ensure that the USB cable from the CY8CKIT-042 is connected to the PC in this step; otherwise, the motor will not
rotate.
2. Press the SW2 button to start motor rotation (see Figure 5-19). If the motor does not rotate and you observe LED2
blinking, it indicates that an error has occurred. Ensure that step 1 through step 5 have been executed correctly.
Then, press the Reset button and press the SW2 button again. If LED2 still blinks, there must be a problem in the
hardware or software. To debug this problem, contact Cypress for technical support.
CAUTION
Do not remove jumpers while the kit is powered.
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CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 42
5.4.6 Adapting the Code Example to another Motor
This code example can be changed to rotate other sensorless BLDC motors. Some parameters in the project firmware need
to be modified according to specific motor characteristics and functional requirements.
5.4.6.1 Tuning Parameters Overview
This code example provides two structure definitions for tuning purposes: BLDC_Config_T and BLDC_Control_T.
“BLDC_Config_T” is defined in the parameters.h file. It contains all the constant parameters used in BLDC rotation. The
following code illustrates the members of the “BLDC_Config_T” structure.
typedefstruct _BLDC_Config
{
/*-------------------------------------------------------------*
* motor parameters *
*-------------------------------------------------------------*/
uint8 polePairNumber;
/*-------------------------------------------------------------*
* general parameters *
*-------------------------------------------------------------*/
Direction_T direction;
uint16 initSpeedRefRpm;
/*-------------------------------------------------------------*
* PID parameters *
*-------------------------------------------------------------*/
Uint32 kp;
Uint32 ki;
/*-------------------------------------------------------------*
* preposition parameters *
*-------------------------------------------------------------*/
uint16 prepositionTime;
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CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 43
uint16 prepositionDuty;
/*-------------------------------------------------------------*
* startup parameters *
*-------------------------------------------------------------*/
uint16 startDuty;
uint16 freerunDuty;
uint16 startCheckPeriod;
uint8 startStageWait;
uint8 decStageInterval;
uint8 freerunStageWait;
uint8 accStageInterval;
uint8 accStageWait;
uint8 accDutyStep;
uint8 accTimeStep;
/*-------------------------------------------------------------*
* normal run parameters *
*-------------------------------------------------------------*/
uint8 speedCloseLoopWait;
uint8 zcCheckSkipCount;
}BLDC_Config_T;
A variable of “BLDC_Config_T” is defined in the BLDCController.c file as follows.
BLDC_Config_T BLDC_Config;
The parameters in “BLDC_Config_T” are initialized in the BLDC_ParameterInit function (see the following code), which
is executed only once when the system powers up. Generally, these parameters should not be changed during motor
rotation. A number of macros are also defined in the parameters.h file to provide the initial value. You can modify the macro
values for tuning based on application requirements or different motors. Note that macro values should be modified before
the code example is compiled. Once the project is compiled, changing macro values has no effect.
However, if some additional debugging code is developed to support run-time tuning via the communication interface, such
as RS232, SPI, or I2C, real-time updating of the parameters in the “BLDC_Config” variables is possible. Note that the code
example included with the kit does not include this kind of debugging code. Kit users must develop it themselves.
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 44
void BLDC_ParameterInit(void)
{
/* motor pole-pair number */
BLDC_Config.polePairNumber = MOTOR_POLE_PAIR_NUM;
/* motor rotation direction, options are CLOCK and COUNTER_CLOCK */
BLDC_Config.direction = CLOCK;
/* speed reference in RPM unit */
BLDC_Config.initSpeedRefRpm = INIT_SPEED_REF_RPM;
/* kp for PID control */
BLDC_Config.kp = KP_INITIAL_VALUE;
/* ki for PID control */
BLDC_Config.ki = KI_INITIAL_VALUE;
BLDC_Config.startDuty = START_PWM_DUTY;
BLDC_Config.freerunDuty = FREERUN_PWM_DUTY;
BLDC_Config.startCheckPeriod = START_ZC_CHECK_PERIOD;
BLDC_Config.startStageWait = START_STAGE_WAIT_COUNT;
BLDC_Config.decStageInterval = DEC_STAGE_INTERVAL;
BLDC_Config.freerunStageWait = FREERUN_STAGE_WAIT_COUNT;
BLDC_Config.accStageInterval = ACC_STAGE_INTERVAL;
BLDC_Config.accStageWait = ACC_STAGE_EXEC_COUNT;
BLDC_Config.accDutyStep = ACC_STAGE_DUTY_STEP;
BLDC_Config.accTimeStep = ACC_STAGE_TIME_STEP;
BLDC_Config.prepositionTime = PREPOSITION_WAIT_TIME;
BLDC_Config.prepositionDuty = PREPOSITION_PWM_DUTY;
BLDC_Config.speedCloseLoopWait = SPEED_CLOSE_LOOP_DELAY;
BLDC_Config.zcCheckSkipCount = ZC_CHECK_SKIP_COUNT;
}
Another structure is “BLDC_Control_T,” which is defined in the BLDCController.h file. It contains the system running
status, such as the current running speed in RPM, the output of the PID control, and so on. This structure is updated in real
time during motor rotation. Monitoring these values is helpful in understanding system performance and troubleshooting.
The following code illustrates the members of the “BLDC_Control_T” structure.
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CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 45
typedefstruct _Run_Control
{
uint8 runFlag;
Error_Code_T errorCode;
uint8 sector;
uint8 checkFallingEdge;
uint8 inNormalRun;
uint16 speedMeasuredRpm;
uint16 speedRefRpm;
uint16 speedGivenRpm;
uint16 commutateStamp;
uint16 zeroCrossStamp;
uint16 zeroCrossPeriod;
uint16 delayTime;
int32 pidOutput;
int32 pidSpeedErr;
}BLDC_Control_T;
A variable of “BLDC_Control_T” is defined in the BLDCController.c file as follows:
BLDC_Control_T BLDC_Control;
A macro (see the following code) is defined to reset the values of “BLDC_Control” in the BLDCController.c file. This macro
is executed in the BLDC_ControllerInit function when the system powers up, and in the BLDC_Start function before
the motor starts rotation every time.
#define BLDC_CONTROL_INIT_CODE {\
BLDC_Control.runFlag = FALSE;\
BLDC_Control.errorCode = NO_ERROR;\
BLDC_Control.sector = 1;\
BLDC_Control.checkFallingEdge = FALSE;\
BLDC_Control.inNormalRun = FALSE;\
BLDC_Control.speedMeasuredRpm = 0;\
BLDC_Control.speedRefRpm = 0;\
BLDC_Control.speedGivenRpm = 0;\
BLDC_Control.commutateStamp = 0;\
BLDC_Control.zeroCrossStamp = 0;\
BLDC_Control.zeroCrossPeriod = 0;\
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CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 46
BLDC_Control.delayTime = 0;\
BLDC_Control.pidOutput = 0;\
BLDC_Control.pidSpeedErr = 0;\
}
5.4.6.2 Tuning Startup Procedure
The startup procedure is important for the sensorless BLDC application. At the beginning of startup, the BEMF is not high
enough to detect a stable zero-crossing point, which is used in sensorless control for commutation. The BLDC motor must
rotate at a certain speed to generate a high enough BEMF in open-loop mode for a specified time. Then the system
switches to position closed-loop mode for zero-crossing point tracking and commutation on demand. After position closedloop mode is stable, the system enables speed closed-loop mode to force motor rotation close to a given speed reference.
Once speed closed-loop mode is stable, the BLDC motor works in normal run mode.
The tuning startup procedure is performed for many possible reasons. One is that a different startup load is applied to the
motor; another is that a changing motor requires performance tuning to match the new motor characteristics. The code
example provides a multistage startup procedure, as shown in Figure 5-29. This procedure contains six stages, and the
PWM duty cycle varies for the different stages.
Figure 5-29. Multistage Startup Procedure
A firmware counter is used to detect the zero-crossing for each stage. Stage switching happens only when the firmware
counter is timed out. “startCheckPeriod” sets the timeout period for the firmware counter.
uint16 startCheckPeriod;
Stage PREPOSITION aligns the motor rotor to a given position for a while and prepares it for the starting rotation. Two
parameters are tunable for this stage. “prepositionTime” is a threshold for an internal counter that counts how many
times stage PREPOSITION is executed. A larger “prepositionTime” value lengthens the duration of the PREPOSITION
stage. “prepositionDuty” is the duty cycle for stage PREPOSITION. A larger “prepositionDuty” value generates a larger
preposition torque.
uint16 prepositionTime;
uint16 prepositionDuty;
startDuty
freerunDuty
PREPOSITION
START
DECREASE
FREERUN
FAIL
Duty
Cycle
ACCELERATION
prepositionDuty
Time
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CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 47
Stage START makes the motor rotate from the stop state. Change “startDuty” for a different load status. A larger value
generates a larger startup torque for a heavy load. “startStageWait” indicates the duration for which START is
executed. It is a threshold for an internal counter that counts how many times stage START is executed. A larger
“startStageWait” value lengthens the duration of stage START.
uint16 startDuty;
uint8 startStageWait;
Stage DECREASE follows stage START. In this stage, the duty cycle of the PWM is decreased by 1 every time until the
duty reaches the “freerunDuty”, which is the minimum duty cycle for the startup procedure. Then the motor maintains
rotation in accordance with the “freerunDuty” duty cycle in stage FREERUN. “decStageInterval” sets the interval
between two decrease operations. A larger value results in a slower slope of the decrease curve. ”freerunStageWait”
indicates how long stage FREERUN is executed. It is a threshold for an internal counter that counts how many times stage
FREERUN is executed. A larger “startStageWait” value lengthens the duration of stage FREERUN.
uint16 freerunDuty;
uint8 decStageInterval;
uint8 freerunStageWait;
After stage FREERUN, the motor starts to accelerate for a higher BEMF in stage ACCELERATION. “accStageInterval”
sets the interval between two increase operations. “accStageWait” indicates how long the stage ACCELERATION is
executed. A larger “accStageWait” value lengthens the duration of stage ACCELERATION. “accDutyStep” sets the
increase step for the duty cycle, while “accTimeStep” sets the decrease step for the period of commutation in open loop.
uint8 accStageInterval;
uint8 accStageWait;
uint8 accDutyStep;
uint8 accTimeStep;
If the system cannot detect a valid continuous zero-crossing point in the previous stages, the startup procedure is
considered a failure. The system running stage is set as “FREERUNFAILED,” and error code is set as
“FREERUN_ERROR.”
If a continuous zero-crossing is detected within a sequence of timeout events, the system switches to position closed-loop
mode, no matter which stage of the procedure is occurring. The system then waits for a specified time to enable speed
closed-loop mode. This waiting time is specified by “speedCloseLoopWait”. It is a threshold for an internal counter that
counts how many times position closed-loop mode is executed. A larger “speedCloseLoopWait” value lengthens the
duration of position closed-loop mode.
uint8 speedCloseLoopWait;
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CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 48
5.4.6.3 Tuning for Different BLDC Motors
When changing the motor, some motor-related parameters or macros need modification, as listed in Table 5-1.
Table 5-1. Motor-Related Parameters for Sensorless BLDC Motor Control Code Example
No.
Parameter
Location
Comment
1
polePairNumber
BLDC_Config_T
Pole-pair number for motor
2
direction
BLDC_Config_T
Desired rotation direction
3
NORMAL_DC_VOLTAGE
Parameters.h
DC bus voltage in volts
4
MAX_SPEED_REF_RPM
Parameters.h
Maximum rotation speed
5
MIN_SPEED_REF_RPM
Parameters.h
Minimum rotation speed
6
START_PWM_DUTY
Parameters.h
The duty cycle of startup. Its value depends on input voltage,
motor characteristic, and load status. Generally, it is tuned
based on the try-observe method. The more the load, the
larger the duty cycle value.
7
FREERUN_PWM_DUTY
Parameters.h
Default duty cycle for free run in open loop
8
INIT_SPEED_REF_RPM
Parameters.h
Initial speed reference after motor enters closed loop.
Generally, it should be 15 to 25 percent of the maximum
speed if no value is specified.
5.4.6.4 Status LED Display and Error Code
Multiple error states are defined in the BLDCController.h file as follows.
typedefenum _Error_Code
{
NO_ERROR, /* no error happens */
ZC_CHECK_ERROR, /* zero-crossing detection failure */
OV_ERROR, /* overvoltage happens */
UV_ERROR, /* undervoltage happens */
FREERUN_ERROR, /* freerun stage fails, fail to enter close loop */
ANY_ERROR, /* for any unknown error */
ERROR_SIZE /* variable to store count of error types */
}Error_Code_T;
A status LED is used to display the system status. When the motor is rotating normally, the LED is turned on. When the
motor is stopped normally, the LED is turned off. When an error occurs, the status LED flashes. The number of flash times
indicates the error code. For example, if the status LED flashes three times, the UV_ERROR has occurred.
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 49
5.5 Sensorless FOC Motor Control Code Example
5.5.1 Sensorless FOC Background
5.5.1.1 PMSM Introduction
PMSM is the most popular motor type in industrial, home appliance, and automotive medium- and high-end applications. As
Figure 5-30 shows, PMSM has a structure similar to that of the AC induction motor. PMSM has a wound stator and a
permanent magnet rotor that provide sinusoidal flux distribution in the air gap, making the BEMF inform a sinusoidal shape.
The construction of the stator and rotor can provide lower rotor inertia and high power efficiency and reduce the motor size.
Figure 5-30. PMSM Structure
Depending on how magnets are attached to the rotor, PMSM motors can be classified into two types: surface PMSM
(SPMSM) and interior PMSM (IPMSM). Figure 5-31 illustrates the differences between these two types. SPMSM mounts all
magnet pieces on the surface, and IPMSM places magnets inside the rotor. SPMSM is widely used for simple
manufacturing and assembling, while IPMSM optimizes performance by the specific placement of magnets. “PMSM” refers
to “SPMSM” in the remainder of this guide, unless otherwise specified.
Figure 5-31. SPMSM and IPMSM Structural Differences
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CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 50
5.5.1.2 PMSM Mathematic Model
A mathematical model of PMSM motors is essential for control and performance analysis. Before discussing any model,
some assumptions should be set.
• PMSM winding connection is in “Y” type; any delta connections need to convert to “Y” type.
• Magnetic saturation is neglected.
• Eddy currents and hysteresis losses are negligible.
Figure 5-32 illustrates a three-phase stator reference frame, which is the basic PMSM model. In this frame, the axis of A, B,
C is aligned with the direction of the PMSM stator windings; is the flux linkage vector of the rotor magnet. The rotor
rotates at angular speed and generates an angle between and phase A.
Figure 5-32. Three-Phase Stator Reference Frame
The voltage on the stator winding can be presented as:
Where,
Stator voltage vector
Stator resistance
Stator current vector
Differential operator
Stator flux linkages
The stator winding flux linkages can be written as the sum of the flux linkages due to their own excitation, mutual flux
linkages resulting from other winding currents, and flux linkages from magnet sources of the rotor. As stator windings have
120o angles in mechanical space, the stator flux linkages can be expressed as follows:
Where,
Equivalence inductance of stator
Mutual equivalence inductance of stator
Amplitude of rotor flux linkages
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This model is high order, strongly coupled, and nonlinear. It is difficult to analyze and control torque and flux; therefore, a
two-phase d-q model is developed to simplify the three-phase model. The d-q model is based on a rotating two-phase
reference frame that is aligned with the rotor flux. It first converts the three-phase reference frame (a, b, c) to a two-phase
stationary reference frame (α, β) using the Clarke transformation (see Figure 5-33).
Figure 5-33. Reference Frame Conversion Using Clarke Transformation
The current vector in the (α, β) frame is:
For “star” type winding connections, the sum of three-phase currents is zero.
Therefore, the current vector on the α-axis and β-axis can be presented as:
Then a Park transformation converts the (α, β) frame to a rotating two-phase reference frame (d, q) aligned with the rotor
flux (see Figure 5-34). The current vectors in the (d, q) frame are:
Figure 5-34. Reference Frame Conversion Using Park Transformation
Now the voltage in the d-q frame can be calculated by and .
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CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 52
The torque equation is:
Where,
= Pole-pair number of rotor
Note that and have no relationship with electrical angle , and is equal to for SPMSM; therefore, the torque can
be expressed as
Both and are related to motor characters, and they are not affected by motor operation. Therefore, torque is
proportional only to the q-axis current in the d-q model, which provides a simple method to control torque generation.
5.5.1.3 Field-Oriented Control
FOC, also called “vector control,” employs the d-q model. It is a control technique used in PMSM and AC induction motors
for high-performance motor applications. It can operate smoothly over a wide speed range and is capable of fast
acceleration and deceleration. It can easily control the motor torque to reduce ripple and achieve smooth rotation with lower
noise and vibration.
Figure 5-35 illustrates the control block diagram for FOC. Compared to the basic d-q model, it introduces four new blocks:
Speed and Position Estimation, Speed Regulator, Current PI Regulators, and Space Vector PWM (SVPWM).
Figure 5-35. Sensorless FOC Block Diagram
Speed and Position Estimation samples the feedback signal from the motor and calculates the angular speed and position
of the rotor. This information is employed in the Clarke and Park transformations to convert three-phase currents to and
in the d-q model.
Speed Regulator and Current PI Regulators employ control algorithms to ensure that rotation speed and d-q current remain
close to the commanded values, which are set by the user or host system. The output of Current PI Regulators is
transformed to three-phase voltages by inverse Clarke and Park transformation.
The SVPWM, also called “SVM”, is used to generate a sinusoidal current waveform to feed to the stator coils. Suppose
through are the six power transistors that shape the output, and are the upper transistors. When an
upper transistor is switched on, the corresponding lower transistor is switched off.
Current PI
Regulators
Inverse
Park/Clarke
Transformation
SVPWM
3
Phase
Inverter
Current
Sampling and
Reconstruction
Speed and
Position
Estimation
Clarke
Transformation
Park
Transformation
Speed
Regulator
PMSM
Motor
i_a_raw
i_b_raw
i_a
i_b
i_c
i_ α i_ β i_
α
i_ β i_d
i_q
θ
ω
ω
i_d _ ref
i_q _ ref
u_
α
u_
β
u_a
u_b
u_c
phase a
phase b
phase c
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CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 53
If recording the ON state of the upper transistor as “1” and the OFF state as “0”, there are eight possible combinations of
ON and OFF states. Corresponding to these different combinations are eight outputs, as shown in Table 5-2. , , are
the phase (line-to-neutral) voltages, while , , are the line-to-line voltages.
Table 5-2. Output Combination in Three-Phase Frame
ON/OFF State
Line-to-Line Voltage (Vdc)
Phase Voltage (Vdc)
1 0 0
1 0 –1
2/3
–1/3
–1/3 1 1
0
0 1 –1
1/3
1/3
–2/3 0 1
0
–1 1 0
–1/3
2/3
–1/3
0 1 1
–1 0 1
–2/3
1/3
1/3
0 0 1
0
–1 1 –1/3
–1/3
2/3 1 0
1
1
–1 0 1/3
–2/3
1/3
0 0 0
0 0 0 0 0
0
1 1 1
0 0 0 0 0
0
The eight combinations in Table 5-2 can be converted to six nonzero vectors and two zero vectors, as shown in
Figure 5-36. The nonzero vectors form the axes of a hexagon, and the angle between any adjacent two nonzero vectors is
60o. This divides the hexagon into six sectors: I through VI. The zero vectors are at the origin and apply zero voltage to a
three-phase load. The eight vectors, called the “basic space vectors”, are denoted by , , , , , ,
and .
Figure 5-36. Space Vectors
Assume is the desired reference voltage in the (α, β) frame. The reference voltage can be produced by a
combination of basic space vectors using the SVPWM technique. Figure 5-37 shows an example. is in sector I
( and the period of PWM is . is the respective duration for appearance; is the respective duration for
appearance; is the duration of zero vectors.
Figure 5-37. Voltage Vector in Sector I
Then, the can be expressed as:
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CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 54
Therefore,
Then,
According to the ON/OFF state of the upper transistor in , and zero vector, the can be generated by changing
the duty cycles of PWMs applied to the inverter.
5.5.1.4 Sensorless FOC Technique
The Park transformation requires the rotor position information, which is presented as the angle between the rotor flux
linkage and α-axis. This is calculated by the Speed and Position Estimation block based on the motor feedback signals.
In a sensored design, the feedback signal comes from specific sensors, such as Hall sensors or optical encoders. These
sensors not only increase the total cost of the motor system, but they also require maintenance, as they may fail during the
motor’s lifetime. The sensorless technique removes the physical sensors and replaces them with an algorithm in a
microcontroller.
The idea of the sensorless technique is to estimate position based on the BEMF due to its relationship with angle . The
BEMF can be measured directly. However, the measurement circuitry has to handle high voltages; therefore, this technique
is not encouraged.
The two-phase voltages in the (α, β) frame can be expressed as:
Where,
Resistance of winding phase
for SVPWM (where L is inductance)
Differential operator
BEMF excited by rotor magnet
In the digital domain, the equation can be changed to:
Where,
Period of PWM on inverter
Solving for as:
Note that and are the motor characteristics, which can be measured by equipment. is a constant system parameter,
is a sampling result in the last control cycle, and is the calculation result in the last control cycle. Therefore, if
is given as , an estimated current value can be obtained. The “*” here indicates it is a value estimated
by algorithm and not directly measured.
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CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 55
Comparing with the actual current value sampled by ADC, an error between these two can be fed to
adjust the given value for better estimation. This process is repeated until the error between
is as small as required. Then the given value represents the actual BEMF .
The can be obtained in the same way, and the angle can be calculated as:
Angular speed is calculated by accumulating over m samples and is multiplied by speed constant .
Thus, the position and speed information are retrieved from the estimated BEMF.
5.5.2 Sensorless FOC Motor Control Code Example Overview
Figure 5-38 illustrates the block diagram of the Sensorless FOC Motor Control code example based on PSoC 4.The input
control signals to the PSoC 4 device are the following.
• Speed command: An analog input pin that measures the voltage across a potentiometer to set the desired speed
of rotation (one analog input pin).
• Motor current measurement: Two analog input pins to detect the motor winding current by sensing resistors.
Then the signal is routed to internal opamps to be amplified and filtered.
• Start/Stop control: Digital input connected to a switch to start and lock rotation of the motor (one digital input pin).
Outputs from the PSoC 4 device are power device driver signals.
• PWM signals to the high side of the MOSFET driver (three digital output pins)
• PWM signals to the low side of the MOSFET driver (three digital output pins)
• Overcurrent limit voltage set by the internal IDAC and an outside resistor
Figure 5-38. Sensorless FOC Motor Control Code Example Block Diagram
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5.5.3 Control Schematic Overview
The Sensorless FOC Motor Control code example firmware is developed in PSoC Creator 4.2. Its schematic has one page.
Figure 5-39 shows the PWM design in the Sensorless FOC Motor Control code example schematic. The three TCPWM
Components generate three couples of the center-aligned and complemented SVPWM signal according to the FOC
algorithm.
Figure 5-39. PWM Schematic
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Figure 5-40 shows the ADC design in the Sensorless FOC Motor Control code example schematic. SAR ADC is triggered in
every PWM cycle by the “cc” signal, and it samples for the following signals: two-phase winding currents, bus voltage, and
potentiometer divider voltage. “Opamp_A” and “Opamp_B” are internal opamps to amplify and filter the motor winding
currents combining the external resistors and capacitors network. PWM_D is synchronous with the carrier frequency, the
set of cc point is 0.5s advanced than un point, so that could get a max output duty.
Figure 5-40. ADC Schematic
Figure 5-41 shows the Over Current Protection design in the Sensorless FOC Motor Control code example schematic.
IDAC_IbusPt connects to a resistance and generates a reference voltage to LPComp.
Figure 5-41. Over Current Protection Schematic
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5.5.4 Firmware Introduction
Figure 5-42 gives the firmware execution flow. Most of the FOC calculation is done in an ISR triggered by the PWM UN
event. As there is only one UN for each PWM period, the ISR is executed per 100µs (10-kHz PWM on the inverter), which is
also the control cycle period for the PSoC 4 FOC implementation.
The FOC algorithm requires that the PWM duty cycle be updated for each control period, while other functions, such as
communication with other systems, set speed, LED, and so on do not require real-time processing. Therefore, these
functions are executed in the main routine.
Figure 5-42. Firmware Execution Flow Chart
Start
Start
Initialization
Initialization
Motor Stop
Motor Stop
ErrorType ==0&&Target
Speed>0
ErrorType ==0&&Target
Speed>0
Y
N
Output
Output
Y
Position Estimate
Position Estimate
Speed Loop
Speed Loop
Clark,Park
Clark,Park
Current Loop
Current Loop
InvPark
InvPark
SVPWM
SVPWM
Enter PWM ISR
Enter PWM ISR
Enter ADC ISR
Enter ADC ISR
Get 4 Channels Data
Get 4 Channels Data
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 59
To create a multilayer and extensible library architecture for the Cypress motor control solution, the Sensorless FOC Motor
Control code example utilizes a multilayer structure. Figure 5-43 shows the layer diagram of the code example.
Figure 5-43. Sensorless FOC Motor Control Code Example Layer Diagram
Motor Control
Library
Motor Control
Library
Module
App
User
PSoC Chip
Peripherals/Components
Coordinate
Transform,Filter,Math,Pid,Svpwm
ADC,Motor Startup,Motor Ctrl,Field
Weaken,Limitation,Observer,speed
set,Protect
Chip Init,ISR,Hardware
Config,Customer Interface
A description of each layer follows.
Module Layer
• Fundamental control modules (Clarke/Park transformation and so on)
• General filters (1-order LPF, 2-order BWF, 2-order filter)
• Trigonometric and math function (sin, cos, arctan, sqrt, abs, and so on)
• Standard PID calculation
• SVPWM
App Layer
• ADC sample, offset detect.
• Motor startup flow
• Motor control flow
• Field weaken
• Limitation calculation
• Position estimate
• Basic fault detection (over current, power over range, motor lock)
• Speed set and running direction
User Layer
• Initialization for PWM start and stop, PWM configuration
• Interrupt entrance
• Motor running parameters set and so on.
• Definition of sample channel, ADC reference and clock frequency
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 60
5.5.5 Running the Sensorless FOC Motor Control Code Example
5.5.5.1 Step 1 – Configure CY8CKIT-042
Select 5 V as the VDD power at jumper J9 on the Pioneer Kit. Ensure to keep the USB cable connected to the Pioneer Kit
because the Pioneer Kit does not provide a 5 V converter. It gets 5 V power directly from the USB port of the PC.
Figure 5-44 shows the configuration.
Figure 5-44. CY8CKIT-042 Configuration for Sensorless FOC Motor Control Code Example
5.5.5.2 Step 2 – Configure CY8CKIT-037
Configure the board via jumpers J13–J24 for the Sensorless FOC Motor Control code example (“BLDC 2-SHUNT FOC” row
in Figure 5-6). Figure 5-45 shows the EVK board configured for the Sensorless FOC Motor Control code example.
Figure 5-45. CY8CKIT-037 Configuration for Sensorless FOC Motor Control Code Example
5.5.5.3 Step 3 – Plug CY8CKIT-037 into CY8CKIT-042
Plug the EVK board into the Pioneer Kit via connectors J1–J4, as shown in Figure 5-16.
Select 5V
as VDD
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 61
5.5.5.4 Step 4 – Connect the Power Supply and Motor
Connect the BLDC motor windings to J9 and J10 on the EVK board, and then connect the 24 V power adapter to J7, as
shown in Figure 5-46. LED1 glows, indicating that the kit is powered. If it is not glowing, the fuse F2 may be broken.
Replace F2 with the backup fuse provided with the kit.
Figure 5-46. Connect Motor and Power Supply
5.5.5.5 Step 5 – Build the Project and Program PSoC 4
Open the Sensorless FOC Motor Control code example in PSoC Creator 4.2 or later version, as shown in Figure 5-47.
Choose Build > Build Sensorless FOC Motor Control to start building the project, and then choose Debug > Program to
program the chip.
Figure 5-47. Open the Sensorless FOC Motor Control Code Example
CAUTION
During the debugging process, if you modify the code in the firmware, make sure that the
changes do not turn on both the high-side and low-side MOSFETs.
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 62
5.5.5.6 Step 6 – Rotate the Potentiometer R38 to Start Motor Rotation
Rotate the potentiometer R38 to change the motor rotation speed (see Figure 5-19). Press the SW2 button to set the motor
running direction. If the motor does not rotate, it indicates that an error has occurred. If so, first ensure that step 1 through
step 5 have been executed correctly. Then press the Reset button and rotate the potentiometer R38 again. If the motor still
does not rotate, there must be a problem in the hardware or software. Contact Cypress for technical support.
CAUTION
Do not remove jumpers while the kit is powered.
5.5.6 Adapting the Code Example to another Motor
This code example can be used to control several different types of three-phase PMSM motors, and the motor performance
is closely related to the motor parameters. So the motor-related parameters in the project firmware need to be modified
according to specific motor characteristics. The motor-related parameters are defined in customer_interface.c. Table 5-3
shows the motor-related parameters.
Table 5-3. Motor-Related Parameters for Sensorless FOC Motor Control Code Example
Variable’s Name in Project
Variable’s Value
Comments
int32_t Motor_i32PolePairs
4
rotor pole pairs
float32_t Motor_f32Ld
0.006
motor Ld
float32_t Motor_f32Lq
0.006
motor Lq
float32_t Motor_f32Res
1.1
motor resistance between two phases
float32_t Motor_f32Ke
2.83
inductive voltage constant between two phases
You can modify these parameters in customer_interface.c.
Table 5-4 shows the hardware-related parameters, PID parameters and motor startup parameters.
Table 5-4. Control-Related Parameters
Variable’s Name in Project
Variable’s Value
Comments
float32_t Motor_f32IuvwSampleResistor
0.03
Iuvw sample resistor
float32_t Motor_i32IuvwAmplifierFactor
4.16
Iuvw calculation factor
int32_t Motor_i32IuvwOffsetNormal
2048
the middle value of 12-bits ADC
int32_t Motor_i32IuvwOffsetRange
150
ADC offset range of Iuvw sampling
int32_t Motor_i32IuvwOffsetCheckTimes
64
Iuvw ADC sample offset check times
float32_t Motor_f32DeadTimeMicroSec
0.8f
Dead timer us
uint16_t Motor_u16CarrierFreq
10000
motor carry frequency
float32_t Motor_f32Dki
0.04f
d axis current PI regulator integral
constant
float32_t Motor_f32Dkp
0.50f
d axis current PI regulator proportion
constant
float32_t Motor_f32Qki
0.04f
q axis current PI regulator integral
constant
float32_t Motor_f32Qkp
0.50f
q axis current PI regulator proportion
constant
float32_t Motor_f32LowSpdKi
0.005f
Low speed PI regulator integral
constant
float32_t Motor_f32LowSpdKp
0.25f
Low speed PI regulator proportion
constant
float32_t Motor_f32Ski
0.005f
High speed PI regulator integral
constant
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 63
Variable’s Name in Project
Variable’s Value
Comments
float32_t Motor_f32Skp
0.25f
High speed PI regulator proportion
constant
uint16_t Motor_u16ChgPiSpdHz
30
PID parameters change at this speed
uint8_t Motor_u8RunLevel
4
1->orientation, 2->open loop running,
3->closed loop running, 4->change speed
enable
int16_t Motor_i16Q8_OrientEndIqRef
Q8(0.5)
orientation end current
int16_t Motor_i16Q8_OrientInitIqRef
Q8(0)
orientation initial current
float32_t Motor_f32OrientIqrefIncAPS
1.0f
orientation current added per sec
float32_t Motor_f32OrientTime
0.0f
orientation time,Second(if 0,skip this
step)
uint16_t Motor_u16OpenLoopSpdInitHz
3
force start initial speed
uint16_t Motor_u16OpenLoopSpdEndHz
3
force start end speed(if init= end,
skip this step)
uint16_t Motor_u16OpenLoopSpdIncHz
3
force start speed added per sec
int16_t Motor_i16Q8_OpenLoopInitIqRef
Q8(1.0)
force start q axis initial current
reference
int16_t Motor_i16Q8_OpenLoopEndIqRef
Q8(2.0)
force start q axis current reference
float32_t Motor_f32OpenLoopIqrefIncAPS
2.0f
force start current added per sec
5.6 Single Shunt FOC Motor Control Code Example
5.6.1 Single Shunt FOC Background
The two-shunt sensorless FOC in the Sensorless FOC Motor Control Code Example gets the motor winding current and
estimates the rotor position from two sensing resistors directly in series with two coil current paths. The single-shunt FOC
technique uses only one sensing resistor to get the bus current and reconstruct the two-phase motor winding current. It then
estimates the rotor position according to the reconstructed winding current. Compared with the two-shunt FOC technique, it
saves a sensing resistor and a differential amplifier and so reduces the cost.
Figure 5-48 shows the current measurement by the single shunt.
Figure 5-48. Single-Shunt FOC Current Measurement
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 64
The disadvantages of single-shunt FOC are obvious. You need to reconstruct the three-phase motor winding current from
the bus current, so the sinusoidal modulation pattern needs to be modified to allow the bus current to be measured. This
makes the PWM signal generation algorithm more complicated than in the two-shunt Sensorless FOC Motor Control code
example.
As Figure 5-49 shows, there are eight possible combinations of ON and OFF states of PWM. Each state has a different bus
current. When the PWM state is zero vector (000 or 111), the bus current is zero. For the other six states, the following
discussion uses 100 vector to explain the winding current reconstruction.
When PWMA is ON, PWMB and PWMC are OFF (100 state), and current flows from phase A into phases B and C. At this
time, the bus current is iA, as Figure 5-49 shows.
Figure 5-49.Bus Current on 100 PWM Vector
In the same way, you can get the bus current of other PWM states. Table 5-5 shows the relationship between the bus
current and the PWM state.
Table 5-5. Relationship Between Bus Current and PWM State
1H
1L
2H
2L
3H
3L
iBus
1 0 0 1 0 1 iA 0 1 1 0 0 1
IB 0 1 0 1 1 0
IC
0 1 1 0 1 0 -iA
1 0 0 1 1 0 -IB 1 0 1 0 0 1
-IC
So, if you sample bus current twice in one PWM period in a different PWM state, you can get two-phase currents. Then you
can reconstruct the third one.
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 65
5.6.2 Single Shunt FOC Motor Control Code Example Overview
Figure 5-50 illustrates the block diagram of the Single Shunt FOC Motor Control code example based on PSoC 4. The input
control signals to the PSoC 4 device are the following.
• Speed command: Analog input pin that measures the voltage across a potentiometer to set the desired speed of
rotation (one analog input pin)
• Motor current detection: Analog input pin to detect and cut off power to the device driver to protect the motor
when an overcurrent condition is detected (see Control Schematic Overview)
• Vbus: Analog input pin that routes bus voltage to the SAR ADC to monitor the bus voltage
• Start/stop control: Digital input connected to a switch to start and stop the motor rotation (one digital input pin)
Outputs from the PSoC 4 device are power device driver signals.
• PWM signals to the high side of the MOSFET driver (three digital output pins)
• PWM signals to the low side of the MOSFET driver (three digital output pins)
• Overcurrent limit voltage set by the internal IDAC and an outside resistor
Figure 5-50. SingleShunt Sensorless FOC Motor Control Code Example Block Diagram
SAR
ADC
SVPWM
TCPWM
CMP
GPIO
GPIO
PSoC 4
PMSM
Motor
Inverter
12V & 3.3V
Power Supply
24V Power
Supply
/ 2
/3
Bus
Current
Speed
Command
GPIO
IDAC
SAR
ADC
TCPWM
GPIO
/ 2
TCPWM
GPIO
/ 2
Op
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 66
5.6.3 Control Schematic Overview
The Single Shunt Foc Motor Control code example firmware is developed in PSoC Creator 4.2. Its schematic is separated
into two pages according to function. Figure 5-51 shows the “PWM Drive” schematic in the “FOC” page. The three TCPWM
Components generate three couples of the center-aligned and complemented SVPWM signal according to the FOC
algorithm.
Figure 5-51. PWM Drive Schematic
By comparing Figure 5-52 with Figure 5-39, you can see that the PWM duty cycle update and ADC trigger mechanism are
different from the Sensorless FOC Motor Control code example because the current sensing and reconstructing method
has been changed in the Single Shunt FOC Motor Control code example.
Figure 5-52 shows the ADC trigger timing. To avoid impacting the current pulse when the PWM state changes, ADC
sampling is triggered in the middle of two PWM states. So the schematic shows the use of a PWM underflow signal (“un”)
as a trigger source and then the use of a timer (“ADC_Timer”) to create a delay to ensure that the ADC is triggered in the
middle of T1 and T2. The compare value of “ADC_Timer” is updated in real time while the motor is running. In the PWM ov
interrupt ISR, the ADC trigger delay should be set as T1/2. After the ADC is triggered, the ADC trigger delay should be set
as T2/2 in the ADC eoc interrupt ISR.
So, to change the compare value twice in one PWM period, you need two TC events. Then the PWM switch signal is
triggered by “PWM_UPDATE” on both the OV and UN events. The PWM compare value will be updated twice in one
period. The PWM ISR should also be triggered twice on the OV and UN events.
Figure 5-52. ADC Trigger Timing
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 67
Figure 5-53 shows the “Phase Current Sampling” schematic in the “FOC” page. SAR ADC is triggered twice in every PWM
cycle by the “ov” and “cc” signals, and it samples three signals: bus current, bus voltage, and potentiometer divider voltage.
“Opamp_A” is the internal opamp to amplify and filter the bus current combining the external resistors and capacitors
network.
Figure 5-53. Phase Current Sampling Schematic
Figure 5-54 shows the “Overcurrent Protection” schematic. The bus current is measured by an external opamp and routed
to the positive terminal of the internal low-power comparator “LPComp_IbusPt”. The overcurrent threshold is set by an
internal IDAC, “IDAC_IbusPt”, and routed to the negative terminal of “LPComp_IbusPt”. When an overcurrent condition
occurs, “LPComp_IbusPt” will generate an interrupt to disable the PWM output.
Figure 5-54. Overcurrent Protection Schematic
5.6.4 Firmware Introduction
Except for the motor current sensing and reconstruction mechanism introduced in Control Schematic Overview, the control
firmware is similar to the Sensorless FOC Motor Control code example. Refer to Firmware Introduction to learn about the
firmware of the Single Shunt FOC Motor Control code example.
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 68
5.6.5 Running the Single Shunt FOC Motor Control Code Example
5.6.5.1 Step 1 – Configure CY8CKIT-042
Select 3.3 V as the VDD power at jumper J9 on the Pioneer Kit. In this application, the USB cable is used only for burning
firmware, so it can be removed from CY8CKIT-042 after programming. Figure 5-55 shows the CY8CKIT-042 configuration.
Figure 5-55. CY8CKIT-042 Configuration
5.6.5.2 Step 2 – Configure CY8CKIT-037
Configure the board via jumpers J13–J24 for the Single Shunt FOC Motor Control code example (“BLDC 1-SHUNT FOC”
row in Figure 5-6). Figure 5-56 shows the EVK board configured for the SingleShunt FOC Motor Control code example.
Figure 5-56. CY8CKIT-037 Configuration for SingleShunt Foc Motor Control Code Example
5.6.5.3 Step 3 – Plug CY8CKIT-037 into CY8CKIT-042
Plug the EVK board into the Pioneer Kit via connectors J1–J4, as shown in Figure 5-16.
5.6.5.4 Step 4 – Connect the Power Supply and Motor
Connect the BLDC motor windings to J9 and J10 on the EVK board, and then connect the 24 V power adapter to J7, as
shown in Figure 5-46. LED1 glows, indicating that the kit is powered. If it is not glowing, the fuse F2 may be broken.
Replace F2 with the backup fuse provided with the kit.
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 69
5.6.5.5 Step 5 – Build the Project and Program PSoC 4
Open the Single Shunt FOC Motor Control code example in PSoC Creator 4.2 or later version, as shown in Figure 5-57.
Choose Build > Build SingleShunt Foc Motor Control to build the project, and then choose Debug > Program to
program the chip.
Figure 5-57. Open the SingleShunt Foc Motor Control Code Example
CAUTION
During the debugging process, if you modify the code in the firmware, ensure that the changes do
not turn on both the high-side and low-side MOSFETs.
5.6.5.6 Step 6 – Press the SW2 Button to Start Motor Rotation
Press the SW2 button to start motor rotation (see Figure 5-19). If the motor does not rotate and you observe LED2 blinking,
it indicates that an error has occurred. If so, first ensure that step 1 through step 5 have been executed correctly. Then
press the Reset button and press the SW2 button again. If LED2 still blinks, there must be a problem in the hardware or
software. Contact Cypress for technical support.
CAUTION
Do not remove jumpers while the kit is powered.
5.6.6 Adapting the Code Example to another Motor
Refer to Adapting the Code Example to another Motor.
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 70
5.7 Stepper Motor Control Code Example
CY8CKIT-037 does not provide a stepper motor in the kit package. However, the kit does support a stepper motor
controlled with microstep from hardware and firmware. A Stepper Motor Control code example is included in the kit
installation directory. To demonstrate this project, you need to connect your stepper motor to the CY8CKIT-037 kit. The only
requirement for the motor is that the power range should meet the kit specifications.
5.7.1 Stepper Motor Background
The stepper motor is an electromechanical device that converts electrical pulses into discrete mechanical movement. It can
achieve accurate positioning and potential rotation speed control without a feedback sensor. So it is ideally suited for many
measurement and control applications where positional accuracy is important and cost is very low.
The most frequently used stepper motor is the hybrid stepper motor. It has smaller steps, greater torque, and greater
maximum speeds than a variable reluctance and permanent magnet stepper motor. Figure 5-58 shows a sectional view of
the hybrid stepper motor. Both the rotor and stator have teeth, providing a smaller magnetic circuit resistance in some rotor
positions, which improves static and dynamic torque.
Stepper motors have several operational modes, such as full-step mode, half-step mode, and microstep mode. Each mode
controls stepper motor phases in different ways. The full-step and half-step modes have obvious torque rippling and
resonance. Microstep mode changes the current by small steps that split each step into microsteps. When two phases are
turned on and the current on each phase is not equal, the current phase ratio determines the rotor position. Changing the
ratio produces a number of microsteps inside each full step.
Figure 5-58.Hybrid Stepper Motor
Fractional steps are created by scaling torque contributions between windings. Because torque is proportional to the
magnetic flux that is proportional to the current in the winding, the rotor’s position can be controlled by controlling the
current flowing in each winding. To create smooth microsteps between full steps, the current is varied sinusoidally with a
90o phase shift between the two windings, as shown in Figure 5-59.
The current is scaled by controlling the RMS current using a current-mode buck converter, commonly called a “chopper
drive” when used with stepper motors. The phase current is converted into a voltage using a sensing resistor in each phase
ground path. This voltage is routed to a comparator, which disables the output whenever the phase current rises above a
reference. The comparator reference is provided by an IDAC. By changing the IDAC-supplied current limit for each
microstep, the total motor torque remains approximately constant for each step of the sinusoidal current waveform.
Figure 5-59.VDAC Current Limit for Microstep Mode
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 71
5.7.2 Stepper Motor Control Code Example Overview
Figure 5-60 illustrates the block diagram of the Stepper Motor Control code example based on PSoC 4. The input control
signals to the PSoC 4 device are as follows:
• Speed command: An analog input pin that measures the voltage across a potentiometer to set the desired speed
of rotation (one analog input pin).
• Motor current detection: Two analog input pins to detect the motor winding current by sensing resistors. Then
the signal is routed to internal opamps to be amplified.
• PWM kill: Two digital input pins that are the output of external comparators. A high level of this signal will stop
internal PWM output and force the winding current to decrease to the current reference set by the IDAC.
• Start/lock control: A digital input connected to a switch to start and lock rotation of the motor (one digital input
pin).
Outputs from the PSoC 4 device are power device driver signals.
• PWM signals to the high side of the MOSFET driver (four digital output pins).
• PWM signals to the low side of the MOSFET driver (four digital output pins).
• A winding current signal amplified by internal opamps. The signal is routed to positive external comparators and is
compared with the current reference set by the IDAC to construct the winding current chopper circuit.
• The sinusoidal current reference voltage set by the internal IDAC and outside resistors.
Figure 5-60. Stepper Motor Control Code Example Block Diagram
GPIO
SAR
ADC
PWM
Generator
State Machine
( Commutate )
GPIO
GPIO
PSoC 4
Stepper
Motor
Dual H-Bridge
MOSFETs
12V & 3.3V
Power Supply
24V Power
Supply
/ 4
/4
Winding A
Current
Speed
Command
IDAC
GPIO
IDAC
PWM
Generator
State Machine
( Commutate )
GPIO
/ 4
Microstep
Timer
Winding B
Current
Iref A
Iref B
OpOp
CMP CMP
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 72
5.7.3 Control Schematic Overview
The Stepper Motor Control code example firmware is developed in PSoC Creator 4.2. Its schematic is separated into four
pages according to function. Figure 5-61 shows the “PWM and Commutation” page. When the motor phase current is more
than the sinusoidal reference current level, the chopper circuit will output a high level. This high level closes the PWM
output and synchronizes the real motor phase current with the sinusoidal reference current level. “Control_Reg_1” indicates
the current stage of the stepper motor. It is dynamically modified by firmware to commutate two phase windings
independently through “LUT_A” and “LUT_B.”
Figure 5-61. PWM and Commutation Schematic
Figure 5-62 shows the “Current Chopping” page. Internal IDACs generate the sinusoidal reference, employing the internal
opamps circuit sensing, and amplify the winding current. Then the output of the opamps circuit is compared with the
sinusoidal reference current level for each phase in every microstep by external comparators. When the motor phase
current is more than the sinusoidal reference current level, the comparator will output a high level.
Figure 5-62. Current Chopping Schematic
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 73
Figure 5-63 shows the “ADC, Button and Microstep Timer” page. “Timer_1” sets the period of the microsteps. Its overflow
event triggers an interrupt, and winding commutating and sinusoidal current reference value updating are executed in its
ISR. “ADC_SAR_Seq_1” is the SAR ADC to detect and measure bus voltage and potentiometer voltage.
Figure 5-63. ADC, Button, and Microstep Timer Schematic
5.7.4 Firmware Introduction
Figure 5-64 shows the flow chart of the main loop function. The program first initializes and configures the internal
resources of PSoC 4, and then the main loop detects the user’s start-stop command and RPM reference.
Figure 5-64. Main Loop Function Flow Chart
The microstep drive algorithm is processed in the timer overflow ISR in which the microstep length was set.
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 74
Figure 5-65 shows the flow chart of the timer overflow ISR.
Figure 5-65. Timer Overflow ISR Flow Chart
5.7.5 Running the Stepper Motor Control Code Example
5.7.5.1 Step 1 – Configure CY8CKIT-042
Select 3.3V as VDD at jumper J9 on the Pioneer Kit. In this application, the USB cable is used only for burning firmware, so
it can be removed from CY8CKIT-042 after programming. Figure 5-55 shows the CY8CKIT-042 configuration.
5.7.5.2 Step 2 – Configure CY8CKIT-037
Configure the board via jumpers J13–J24 for the Stepper Motor Control code example (“STEPPER” row in Figure 5-6).
Figure 5-66 shows the EVK board configured for the Stepper Motor Control code example.
Figure 5-66. CY8CKIT-037 Configuration for Stepper Motor Control Code Example
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 75
5.7.5.3 Step 3 – Plug CY8CKIT-037 into CY8CKIT-042
Plug the EVK board into the Pioneer Kit via connectors J1–J4, as shown in Figure 5-16.
5.7.5.4 Step 4 – Connect the Power Supply and Motor
Connect the stepper motor windings to J9 and J10 on the EVK board, as shown in Figure 5-67. The wire sequence and
color for the motor windings should be exactly as shown in Figure 5-67. Refer to Motor Winding Connectors for instructions.
Then connect the 24-V adapter to J7. LED1 glows indicating that the kit is powered. If it is not glowing, the fuse F2 may be
broken. Replace F2 with the backup fuse provided with the kit.
CAUTION
Note: The CY8CKIT-037 PSoC 4 Motor Control EVK package does not include a stepper motor.
Cypress recommends that you use a 42-mm (diameter or side length) stepper motor:
42BYGH403AA (with 1.8-degree step angle and 1.65-A phase current). You can also find a stepper
motor from other manufacturers with the same size and electrical parameters.
Figure 5-67. Connect Motor and Power Supply
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 76
5.7.5.5 Step 5 – Build the Project and Program PSoC 4
Open the Stepper Motor Control code example in PSoC Creator 4.2 or later version, as shown in Figure 5-68. Choose
Build > Build Stepper Motor Control to build the project, and then choose Debug > Program to program the chip.
Figure 5-68. Open the Stepper Motor Control Code Example
CAUTION
During the debugging process, if you modify the code in the firmware, ensure that the changes do
not turn on both the high-side and low-side MOSFETs.
5.7.5.6 Step 6 – Press the SW2 Button to Start Motor Rotation
Press the SW2 button to start motor rotation (see Figure 5-19). If the motor does not rotate and you observe LED2 blinking,
it indicates that an error has occurred. If so, first ensure that step 1 through step 5 have been executed correctly. Then,
press the Reset button and press the SW2 button again. If LED2 still blinks, there must be a problem in the hardware or
software. Contact Cypress for technical support.
CAUTION
Do not remove jumpers while the kit is powered.
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 77
5.7.6 Adapting the Code Example to another Motor
This code example can be used to control two phases of the HB (hybrid) stepper motor with microstep algorithm. You need
to modify the motor-related parameters in the project firmware according to specific motor characteristics. You can also
modify parameters related to function, like microstep numbers, RPM, and current level, according to your requirements.
The main parameters are defined by a struct in UI_paras.h as follows.
typedefstruct
{
uint8 dir; /*Direction*/
uint8 microStepPace; /*For Stepper Motor*/
}UI_DATA;
The real struct variable is defined in main.c.
UI_DATA UI_Data;
This struct variable is initialized in main.c by a function as follows:
void MotorInit(void)
{
Control_Start_Write(0);
UI_Cmd.run = FALSE;
UI_Data.microStepPace = 128;/* Set the number of micro-step pace: microstep number =
128 / UI_Data.microStepPace */
UI_Data.dir = CCW; /* Set rotating direction of motor */
}
This function initializes the parameters before the motor begins running. The initializing value is dedicated for the 42-mm
(diameter or side length) stepper motor (42BYGH403AA). If you want to use your own motor and have different functional
requirements like microstep numbers or direction, change the initializing value in this function.
Note: The number of microsteps is equal to “128/UI_Data.microStepPace.” So, if you set UI_Data.microStepPace = 128,
there is only one microstep, which means no microstep pace. So the stepper motor generates high mechanical vibration,
torque ripple, and noise and may stop abruptly at some mechanical resonance points when the potentiometer is varied. So
it is recommended that you set “UI_Data.microStepPace = 1, 2, 4, 8, 16, or 32” to enable the microstep algorithm to make
the motor run more stably and smoothly.
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 78
5.8 Bridge Control Panel Monitor Tool Guide
During the motor control debugging process, you cannot use the step debug because it prevents the CPU from running at
breakpoint, which leads to blockage of the motor rotation and generates a very high current that burns the motor windings.
Therefore, you need to use the real-time debugging tool to monitor the status of the running motor.
The BCP is a very useful and convenient real-time debugging tool provided by Cypress to monitor the motor state in the
debugging process. This section introduces how to configure and use the BCP in real-time debugging for the motor control
application.
5.8.1 BCP Monitoring Overview
Figure 5-69 shows the system structure of real-time debugging for the motor control application. The controller board
(CY8CKIT-042) works as a lower terminal, and the BCP terminal on the PC works as an upper terminal. CY8CKIT-042
sends real-time motor state data through PSoC 4 dedicated UART pins (P4.0 and P4.1), and then data is pushed into the
USB-to-UART bridge controller (CY7C65213) on the driver board (CY8CKIT-037). CY7C65213 repackages the data and
sends it to the upper terminal through the USB cable, so you can see the curve or chart of the real-time motor state data.
Figure 5-69. Real-Time Debugging Structure
5.8.2 Installing the Driver for CY7C65213 USB-to-UART Bridge Controller
The first step in monitoring data on the BCP is to set up the hardware and install the driver program for the USB-to-UART
bridge controller (CY7C65213) on CY8CKIT-037.
Connect the USB cable to CY8CKIT-037 at connector J11. Then, configure the hardware for the Sensored BLDC Motor
Control code example following step1 to step 5 in Running the Sensored BLDC Motor Control Code Example.
Figure 5-70 shows the hardware setup.
Figure 5-70. Hardware Setup for BCP
USB-UART Bridge
CY7C65213
Motor Controller
CY8C4245
CY8CKIT-042
CY8CKIT-037
BCP Terminal
USB
J11
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 79
Connect the other end of J11 to your PC. The PC operating system (Windows 7 in this document) will automatically
recognize the CY7C65213 USB-to-UART bridge controller and search the driver program for it, as shown in Figure 5-71.
Figure 5-71. CY7C65213 USB-to-UART Bridge Controller Recognition
When the operating system gets the driver program, it will automatically install it for CY7C65213. Figure 5-72 shows the
information window that indicates that the driver program installation for the CY7C65213 USB-to-UART Bridge Controller is
finished.
CAUTION
Do not press switch SW2 on the CY8CKIT-037 board during the installation process because the
controller board (CY8CKIT-042) is unable to send any data to the USB-to-UART Bridge Controller
(CY7C65213) during the installation process. Otherwise, the BCP will not work after the
installation. All the code examples included in the kit send data only after the motor is started by
pressing the start/stop switch, SW2.
Figure 5-72. Driver Program Installation Completion
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 80
5.8.3 Upper Terminal Configuration Guide
Each code example contains the lower terminal firmware to send real-time data and attaches two upper terminal
configuration files, .ini and .iic.
This section uses the Sensored BLDC Motor Control code example as an example. Other code examples are similar.
Open Bridge Control Panel (BCP) and select the COM port, and choose Chart > Variable Settings to open the Variable
Settings window, as Figure 5-73 shows.
Figure 5-73. Variable Settings Window
Then, click the Load button to import the variables.ini file into the Sensored BLDC Motor Control code example, as
Figure 5-74 shows. Click the OK button to finish.
Figure 5-74. Import variables .ini File
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 81
You also need to set the baud of BCP communication. Enter the BCP software interface, and choose Tools > Protocol
Configuration to open the Protocol Configuration window, as Figure 5-75 shows. The recommended baud setting is
115,200 bps.
Figure 5-75. Baud (bps) Settings Window
Choose File > Open File to import the Sensored BLDC Control.iic configuration file into the Sensored BLDC Motor Control
code example, as Figure 5-76 shows. Click the highlighted button to start monitoring data defined by the command in the
Editor and Variable Settings windows.
The Editor window shows the BCP monitor 2 variables as a default. “SpeedCur” shows the real-time motor speed, and
“SpeedRef” shows the reference motor speed. You can change or add monitoring variables by changing the command
statement in the Editor window and keeping the Variable Settings window updated synchronously.
Figure 5-76. Bridge Control Panel Editor
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 82
The command structure consists of four parts: start symbol “Rx8”, header, body, and tail as follows:
Rx8 [H=<byte0><byte1> … <byteN>] <byte0><byte1> … <byteK> [T=<byte0><byte1> … <byteM>]
Where “Rx8”is a start symbol that indicates the beginning of the RX8 command.
[H=<byte0><byte1> … <byteN>] is a header with a list of bytes. It is intended for synchronization of the BCP to an
asynchronous input stream. The header part is optional. It can be present or absent in the script. But if it is absent, then the
tail also should be absent. Otherwise, the ScriptEngine syntax analyzer will inform you about a syntax error and mark in red
the incorrect part of the command.
<byte0><byte1> … <byteK> is a body list of bytes. It is a useful packet load that is received by the host and shown in the
Log and Chart subsystems, depending on the variables configuration in the command. The body is a mandatory part of the
command.
[T=<byte0><byte1> … <byteM>] is a tail with a list of bytes. It indicates the end of the RX8 command. The tail is an
optional part of the command. The RX8 command can be present in the BCP script editor analyzer in three ways:
1) Without the header and tail, with only the body. In this scenario, the host does not synchronize with a stream of bytes. It
simply prints bytes received from the USB-Serial device to the Log and on the Chart if variables were configured in the
script, as shown in the following example.
RX8 X X @1Var1 @0Var1 X @3Var2 @2Var2 @1Var2 @0Var2 X X
2) With the header and body, but without the tail. In this scenario, the host synchronizes with a stream of bytes, finding
header bytes in the stream, as shown in the following example.
RX8 [H = 0A 0E 0C] X X @1Var1 @0Var1 X @3Var2 @2Var2 @1Var2 @0Var2 X X
3) With the header, body, and tail. In this scenario, the host synchronizes with a stream of bytes, finding header, body,and
tail bytes in the stream, as shown in the following example.
RX8 [H = 0A 0E 0C] X X @1Var1 @0Var1 X @3Var2 @2Var2 @1Var2 @0Var2 X X [T = 00 FF FF]
All five code examples use this command format: H = 0x55 and T =0XAA. Variables are 16 bits and always in “MSB-LSB”
format.
You can define your own commands by following these rules:
Keep the default configuration, Press SW2 on CY8CKIT-037 to start the motor. You can see the real-time data in the Chart
window, as Figure 5-77 shows. You can use a tachometer to measure the motor speed and check it on the BCP display.
Figure 5-77. BCP Data Display for Sensored BLDC Motor Control Code Example
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 83
Note: Before you complete all the configuration steps in this section (from Figure 5-73 to Figure 5-76), ensure that switch
SW2 on CY8CKIT-037 is not pressed. If you press it, you will not see data display on the BCP Chart window. However, if
you do press SW2, press SW1 on CY8CKIT-037 to reset the motor, and then complete all the configuration steps shown in
Figure 5-73 to Figure 5-76. You can then press SW2 to start the motor and observe the data on the BCP Chart window.
If you want to run the motor and monitor data for long time (more than 8 minutes), the BCP can display only the original
81920 counts (about 7 minutes at 115,200 bps), as Figure 5-78 shows. The later data no longer appears because the BCP
puts all the received data for display in limited stack memory. So if the stack memory is full, the BCP cannot receive and
display new data. If you want to monitor the real-time data for a long time, reconfigure the BCP to make it display only the
latest data, not all the data from the motor or BCP start.
Figure 5-78. Maximum Data Counts on BCP Monitoring
Choose Chart > Variable Settings to open the Variable Settings window. Then select the “AxisX is a time” option and
write a number (minimum: 1, maximum:500000, unit:ms) into the Scroll text box to define the latest time length to make the
BCP display data, as shown in Figure 5-79. Then the stack memory will never be full, and the BCP can always show the
latest data of the defined time length.
Figure 5-79. BCP Reconfiguration
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 84
5.8.4 Lower Terminal Configuration Guide
While the motor is running, MCU CY8C4245 on the controller board gets all motor state parameters and is responsible for
sending them to the BCP upper terminal. Figure 5-80 shows the Serial Communication Block (SCB) Component and
configuration window. It sends motor state data through two dedicated UART pins (P4.0 and P4.1). It is configured as
“UART_BCP”.
Figure 5-80. SCB Component Configuration
Data is sent by function BCPPoll(), located in the main control loop of the firmware. The function code follows:
void BCPPoll()
{
uint8 index = 0;
if(UART_BCP_SpiUartGetTxBufferSize())
return;
/* package header */
bcpTxBuffer[index++] = 0x55;
/* construct BCP data pacakge with speed value, MSB first */
/* current measured speed */
bcpTxBuffer[index++] = (uint8)((UI_Data.speedRpm & 0xFF00) >> 8);
bcpTxBuffer[index++] = (uint8)(UI_Data.speedRpm & 0x00FF);
/* speed reference */
bcpTxBuffer[index++] = (uint8)((UI_Data.speedRpmRef & 0xFF00) >> 8);
bcpTxBuffer[index++] = (uint8)(UI_Data.speedRpmRef & 0x00FF);
/* package tail */
bcpTxBuffer[index++] = 0xAA;
UART_BCP_SpiUartPutArray(bcpTxBuffer, index);
}
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 85
This function sends two motor state variables: UI_Data.speedRpm and UI_Data.speedRpmRef. You can modify the
variable name and add variables by copying the highlighted code and then changing the variable name from
UI_Data.speedRpm to whatever you want.
5.8.5 Reading the Motor Speed Using BCP Commands
The BCP commands are not functional if the tool is invoked after the motor starts rotating.
To view the proper motor rotation status or RPM readings, follow these steps:
1. Connect and configure CY8CKIT-037 on the CY8CKIT-042 Pioneer Kit per the Sensored BLDC Motor Control Code
Example.
2. Program the HEX file.
3. Connect a USB cable at the J11 port of CY8CKIT-037 to enable the motor speed to be viewed in the BCP. (Wait
until driver enumeration is complete.)
4. Open the BCP and import the UART commands related to the Sensored BLDC project. Refer the Upper Terminal
Configuration Guide.
5. Select the appropriate COM port related to USB-to-UART on CY8CKIT-037 (for example: COM17 in Figure 5-76).
6. Move the cursor to the end of the BCP command "RX8 [h=55] @1speedCur @0speedCur @1speedRef
@0speedRef [t=AA]" in the Command window, and press Enter to execute the BCP command once. Then click the
Repeat button to repeat the command execution (If this operation is missing, an error message window is displayed
as shown in Figure 5-81).
Figure 5-81. Error Message that appears when Step 6 is missed while configuring BCP
7. Press the SW2 button on CY8CKIT-037 to start the BLDC motor rotation.
8. Observe the motor speed on the BCP Editor window (see Figure 5-82) and in Chart Window (see Figure 5-83).
Code Examples
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 86
Figure 5-82. Motor Speed in Editor Window
Figure 5-83. Motor Speed in Chart Window
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 87
A. Appendix
A.1. Board Schematics, Board Layout, and BOM
Figure A-1. Board Schematics
Appendix
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 88
Appendix
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 89
Appendix
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 90
Appendix
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 91
Appendix
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 92
Appendix
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 93
Appendix
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 94
Figure A-2. Board Layout (Top Layer)
Appendix
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 95
Figure A-3. Board Layout (Bottom Layer)
Appendix
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 96
A.2. Bill of Materials
Table A-1. Bill of Materials
Item
Qty
Reference
Description
Manufacturer
Mfr Part Number
1 2 C1, C2
CAP CER 1UF 100V 10% X7R 1206
TDK Corporation
C3216X7R2A105K160AA
2 1 C3
CAP CER 8200PF 50V 10% NP0 0603
TDK Corporation
C1608C0G1H822K080AA
3 2 C4, C43
CAP CER 1UF 50V 10% X7R 0603
Taiyo Yuden
UMK107AB7105KA-T
4 1 C5
CAP CER 1800PF 50V 10% NP0 0603
TDK Corporation
C1608C0G1H182K080AA
5 1 C6
CAP CER 0.022UF 50V 10% X8R 0603
TDK Corporation
C1608X8R1H223K080AA
6 1 C7
CAP CER 2700PF 50V 10% NP0 0603
TDK Corporation
C1608C0G1H272K080AA
7 2 C8, C47
CAP CER 1000PF 50V 10% X7R 0603
TDK Corporation
CGA3E2X7R1H102K080AA
8 1 C9
CAP ALUM 22UF 35V 20% SMD
Panasonic
Electronic
Components
EEE-FK1V220R
9 2 C10, C26
CAP CER 0.1UF 50V 10% X7R 0603
TDK Corporation
C1608X7R1H104K080AA
10 1 C11
CAP ALUM 330UF 63V 20% RADIAL
Nichicon
UVZ1J331MPD
11 1 C12
CAP CER 0.1UF 100V 10% X7S 0603
TDK Corporation
CGA3E3X7S2A104K080AB
12 4 C16, C17, C18, C19
CAP CER 10UF 50V 10% X5R 1206
TDK Corporation
C3216X5R1H106K160AB
13 7 C20, C21, C22,
C23, C24, C25, C29
CAP CER 100PF 50V 10% CH 0603
TDK Corporation
C1608CH1H101K080AA
14 6 C35, C36, C37,
C38, C39, C40
CAP CER 330PF 50V 10% NP0 0603
TDK Corporation
C1608C0G1H331K080AA
15 3 C44, C46, C48
CAP CER 0.1UF 16V 10% X7R 0402
TDK Corporation
C1005X7R1C104K050BC
16 1 C45
CAP CER 1UF 16V 10% X5R 0402
TDK Corporation
C1005X5R1C105K050BC
17 1 D1
DIODE SCHOTTKY 100V 3A SMA
Micro
Commercial Co
SK310A-TP
18 1 D2
DIODE SCHOTTKY 60V 7.5A DPAK
STMicroelectroni
cs
STPS15L60CB-TR
19 4 D3, D4, D5, D6
DIODE FAST REC 50V 1A SMA
Micro
Commercial Co
US1A-TP
20 3 D10, D11, D12
DIO, SUPPRESSOR ESD 5VDC 0603
SMD
Bourns Inc
CG0603MLC-05LE
21 1 F1
PTC RESETTABLE 60V 2.50A
KINKAMO
Littelfuse Inc
60R250XMR
22 2 J1, J4
2.54mm PITCH SINGLE ROW 8POS
HEADER, 13mm MATING LENGTH
PROTECTRON
P9101-08-D32-1
23 1 J2
2.54mm PITCH DUAL ROW 18POS
HEADER, 13mm MATING LENGTH
PROTECTRON
P9103-18-D32-1
Appendix
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 97
Item
Qty
Reference
Description
Manufacturer
Mfr Part Number
24 1 J3
2.54mm PITCH SINGLE ROW 10POS
HEADER, 13mm MATING LENGTH
PROTECTRON
P9101-10-D32-1
25 1 J7
CONN, JACK, POWER,2.1mm , MALE,
3PIN, PCB RA, TH
CUI Inc
PJ-102A
26 1 J8
BLACK COLOUR, TERM BLOCK 2POS
SIDE ENT 3.81MM
TE Connectivity
1776113-2
27 2 J9, J10
GREEN COLOUR, TERM BLOCK 2POS
3.81MM PCB HORIZ
FCI
20020327-D021B01LF
28 1 J11
CONN, MINI USB, RCPT R/A, DIP, B
TYPE
TE Connectivity
1734510-1
29 1 J12
ConWTB Wire to Board Connector
2.50mm pitch , “J” Type Vertical Male
Shrouded Header, 5 pin
Wurth Elektronik
688 005 116 22
30
12
J13, J14, J15, J16,
J17, J18, J19, J20,
J21, J22, J23, J24
CONN, HEADER, VERT, SGL, 3POS,
GOLD
PROTECTRON
P9101-03-12-1
31 1 LED1
LED RED CLEAR 0603 SMD
Lite-On Inc
LTST-C190CKT
32 1 LED2
LED GREEN CLEAR THIN 0603 SMD
Lite-On Inc
LTST-C190GKT
33 1 L1
FERRITE CHIP 600 OHM 1500MA 1206
Murata
Electronics North
America
BLM31PG601SN1L
34 1 L2
INDUCTOR POWER 150UH 20% SMD
TDK Corporation
CLF6045T-151M-H
35 2 L3,L4
IND, FERRITE, 220 OHM, 2A, 25%, 0805
Murata
Electronics North
America
BLM21PG221SN1D
36 8 Q1, Q2, Q3, Q4, Q5,
Q6, Q7, Q8
MOSFET N-CH 75V 56A I-PAK
International
Rectifier
IRFU3607PBF
37 3 R1, R44, R50
RES 10.0K OHM 1/16W 1% 0603
TE Connectivity
5-1879337-9
38 5 R2, R64, R73, R74,
R75
RES 2.00K OHM 1/10W 1% 0603 SMD
Vishay Dale
CRCW06032K00FKEA
39 1 R3
RES 143K OHM 1/10W 1% 0603 SMD
Yageo
RC0603FR-07143KL
40 1 R4
RES 18.2K OHM 1/10W 1% 0603 SMD
Yageo
RC0603FR-0718K2L
41 3 R70, R71, R72
RES 8.20K OHM 1/10W 1% 0603 SMD
Vishay Dale
CRCW06038K20FKEA
42 1 R5
RES 16.9K OHM 1/10W 1% 0603 SMD
Vishay Dale
CRCW060316K9FKEA
43 1 R6
RES 9.10K OHM 1/10W 1% 0603 SMD
Vishay Dale
CRCW06039K10FKEA
44 5 R7, R45, R51, R63,
R65
RES 1.00K OHM 1/8W 1% SMD 0603
Vishay Beyschlag
MCT06030C1001FP500
45 1 R10
RES 590 OHM 1/10W 1% 0603 SMD
Vishay Dale
CRCW0603590RFKEA
46 1 R9
RES, 5.49K OHM, 1%, 1/10W, 0603,
SMD
Panasonic-ECG
ERJ-3EKF5491V
Appendix
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 98
Item
Qty
Reference
Description
Manufacturer
Mfr Part Number
47 1 R11
RES 2.4K OHM 1/10W 5% 0603 SMD
Yageo
RC0603JR-072K4L
48 3 R12, R37, R39
RES, 330 OHM, 5%, 200PPM, 1/10W,
0603
Panasonic-ECG
ERJ-3GEYJ331V
49
10
R20, R21, R22,
R23, R24, R25,
R26, R27, R53, R57
RES, 22 OHM, 1%, 200PPM, 1/10W,
0603, SMD
Panasonic-ECG
ERJ-3EKF22R0V
50 3 R34, R35, R36
RES 0.03 OHM 1/2W 1% 1206 SMD
Rohm
Semiconductor
UCR18EVHFSR030
51 1 R38
POT 10K OHM 1/8W CARB VERTICAL
CTS Corporation
296UE103B1C
52 4 R40, R41, R46, R47
RES, 20K OHM, 1%, 100PPM, 1/10W,
0603
Panasonic
Electronic
Components
ERJ-3EKF2002V
53 4 R42, R43, R48, R49
RES 2K OHM 1/10W 1% 0603 SMD
Panasonic
Electronic
Components
ERJ-3EKF2001V
54 5 R52, R56, R60,
R61, R62
RES 1.0K OHM 1/10W 5% 0603 SMD
Vishay Dale
CRCW06031K00JNTA
55 3 R76, R77, R78
RES 3.9K OHM 1/10W 5% 0603 SMD
Yageo
RC0603JR-073K9L
56 1 R82
RES 10.0K OHM 1/10W 5% 0603
Yageo
RC0603JR-0710KL
57 2 R83, R84
RES 1.80K OHM 1/10W 1% 0603 SMD
Vishay Dale
CRCW06031K80FKEA
58 1 R91
RES 4.7K OHM 1/10W 5% 0603 SMD
Panasonic
Electronic
Components
ERJ-3GEYJ472V
59 3 R92, R93, R94
RES 220 OHM 1/10W 1% 0603 SMD
Panasonic
Electronic
Components
ERJ-3EKF2200V
60 2 R103, R104
RES, 0.0 OHM, 1/10W, 5%, 0603, SMD
Panasonic
Electronic
Components
ERJ-3GEY0R00V
61 2 SW1, SW2
SWITCH TACTILE SPST-NO 0.05A 12V
Panasonic
Electronic
Components
EVQ-PE105K
62 2 TP1(GND),
TP2(GND) ,
TP, TEST POINT, 0.063"D, BLACK, TH
Keystone
Electronics
5006
63 3 TP13(+12V),
TP14(Vin),
TP15(VDD)
TP, TEST POINT, RED, 0.063"D, TH
Keystone
Electronics
5005
64 1 U1
IC REG BUCK ADJ 2.5A 20TSSOP
TI
LM5005MHX/NOPB
65 1 U2
IC COMPARATOR DUAL 0.8MA 8-SOIC
Rohm
Semiconductor
LM393DR
66 4 U3, U4, U5, U6
IC DRIVER HIGH/LOW SIDE 8SOIC
International
Rectifier
IR2101STRPBF
67 1 U7
IC OPAMP GP 8.4MHZ RRO SOT23-5
Analog Devices
AD8601ARTZ-R2
Appendix
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 99
Item
Qty
Reference
Description
Manufacturer
Mfr Part Number
68 1 U8
IC, CYPRESS, USB-UART LP, 512BYTE FLASH, QFN-32
Cypress
Semiconductor
CY7C65213-32LTXI
69 1 VR1
VARISTOR 67V 250A 1210
Littelfuse Inc
V60MLA1210H
70 1 PCB
CY8CKIT-037 MOTOR CONTROL
SHIELD PCB
(Size: 3.8 inch x 2.44 inch
No of Layers: 2
Surface Finish: ENIG
Solder Mask color: Red
Board thickness: 1.6mm)
A.3. No Load Components
Table A-2. No Load Components
Item
Qty
Reference
Description
Manufacturer
Manfacturer Part Number
1 1 R105
RES, 0.0 OHM, 1/10W, 5%, 0603,
SMD
Panasonic
Electronic
Components
ERJ-3GEY0R00V
2
15
TP3(Ia), TP4(Ic),
TP5(AH), TP6(AL),
TP7(BH), TP8(BL),
TP9(CH), TP10(CL),
TP11(DH), TP12(DL),
TP16(P0_2),
TP17(P0_1),
TP18(P0_7),
TP19(GND),
TP20(P2_6/VIN_SENSE)
TP, TEST POINT, RED, 0.063"D,
TH
Keystone
Electronics
5005
3 1 F2
FUSE SLOW 125V 2.5A SMD
Littelfuse Inc
045202.5MRL
Appendix
CY8CKIT-037 PSoC® 4 Motor Control Evaluation Kit Guide, Doc. No. 001-92562 Rev. *C 100
A.4. Special Installation Instructions
Table A-3. Special Installation Instructions
Item
Qty
Reference
Description
Manufacturer
Manfacturer Part
Number
1
12
J13, J14, J15, J16, J17, J18, J19,
J20, J21, J22, J23, J24
MINI JUMPER GF 13.5
CLOSE TYPE BLACK WITH
HANDLE
Kobiconn
151-8030-E
2 1 J12
ConWTB Wire To board
Connector 2.50mm pitch, "J"
type Female Terminal
Housing, 5 Pins
Wurth Elektronik
688 005 113 322
3 5 J12 Hall sensor wire Crimping
2.50mm “J” Type Female
Crimp Contact WR-WTB
Wurth Elektronik
688 001 137 22
A.5. Label
Table A-4. Label
Item
Qty
Reference
Description
Manufacturer
1 1 N/A
LBL, Kit Product Identification Label, Vendor Code,
Datecode, Serial Number CY8CKIT-037 Motor
Control EVK Rev**(YYWWVVXXXXX)
Cypress Semiconductor
2 1 N/A
LBL, Assembly Adhesive Label, Manufacturing ID
Cypress Semiconductor
3 1 N/A
LBL, QR Code, CY8CKIT-037 Printed Circuit
Assembly, 13mm X 13mm
Cypress Semiconductor
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