Modern motion control applications need more flexibility that can be addressed only with specialized
ICs products. The L6235 is a fully integrated motor driver IC specifically developed to drive a wide range
of BLDC motors with Hall effect sensors. This IC is a one-chip cost effective solution that includes
several unique circuit design features. These features, including a universal decoding logic that allows
the device to be used with most common Hall effect spacing, will be described. The principal aim of this
development project was to produce an easy to use, fully protected power IC. In addition several key
functions as protection circuit and high speed PWM current control allow to drastically reduce the
external components count to meet requirements for many different applications.
1INTRODUCTION
For small-motor applications many appliance designers favor modern three phase brushless DC motors because of the high efficiency (as great as 95%) and small size for a given delivered power. Designers have to
handle control logic, torque and speed control, power-delivery issues and ensure safe operation in every load
condition. The L6235 is a highly i ntegrated, mixed-si gnal power IC that allows to easily design a co mplete motor
control system for BLDC motor. Figure 1 shows the L6235 block diagram. The IC integrates six Power DMOS,
a centralized logi c circuit to decode hall effect sensors and a constant t
chronous mode) plus other added features for safe operation and flexibility.
With MOSFET (DMOS) devices, unlike bipolar transistors, current under short circuit conditions is, at first approximation, limited b y the R
and the two V
and VSB pins are rated for a maximum of 2.8 A r.m.s. and 5.6 A peak (typical values). These
SA
values are meant to avoid damaging metal structures, including the metallization on the die and bond wires. In
practical applications, though, maximum allowable current is less than these values, due to power dissipation
limits (see Power Management section).
The device has a built-in Over Current Detection ( OCD) that allows protection against shor t circuits between the
outputs and between an output and ground (see Over Current Detection Section).
2.2 Voltage Ratings and Operating Range
The L6235 requires a single supply voltage (VS), for the motor supply. Internal voltage regulators provide the
5V and 10 V required for the internal circuitry. The operating range for V
undesirable low supply voltage an Under Voltage Lock Out (UVLO) circuit shuts down the device when supply
voltage falls below 6 V; to resume normal operating conditions, V
vided to avoid false intervention of the UVLO function during fast V
DMOS's R
is a function of the VS supply voltage. Actually, when VS is less than 10V, R
DS(ON)
affected, and this is particularly true for the High Side DMOS that are driven from V
obtained through a charge pump fr om the internal 10V supply, which will tend to r educe i ts output v oltage when
goes below 10V. Figure 2 shows the supply voltage of the high side gate drivers (V
V
S
supply voltage (V
).
S
of the DMOS themselves and c ould reach v er y high values. L6235 Out pi ns
DS(ON)
is 8 to 52 V. To prevent working into
S
must then exceed 7 V. The hy steresis is pro-
S
ringings. It should be noted, however, that
S
DS(ON)
supply. This supply is
BOOT
- VS) versus the
BOOT
is adversely
Figure 2. High side gate drivers supply voltage versus supply volta ge.
8
7.6
V
BOOT
- V
[V]
7.2
S
6.8
6.4
6
88.599.51010.5
VS [V]
Note that VS must be connected to both VSA and VSB because the bootstrap vol tage (at V
pin) is the same
BOOT
for the two H-bridges. The integrated DMOS have a rated Drain-Source breakdown voltage of 60 V. However
V
should be kept b elow 52 V , si nce i n nor mal workin g condi tions th e DMOS see a Vds vo ltage that wil l ex ceed
S
supply. In particular when a high-side DMOS turns off due to a phase change (OUT1 in Figure 3), if one of
V
S
the other outputs (OUT2 in Figure 3) is high (during the off-time all active bridges turn their high-side on) the
load current starts flowing in the low-side freewheeling diode and the SENSE pin sees a negative spike due to
a not negligible parasitic inductance of the PCB path from the pin to GND. This spike is followed by a stable
negative voltage due to the drop on R
. The output pin sees a similar behavior, but with a slightly larger
SENSE
voltage due to the forward recovery time of the integrated freewheeling diode and the forward voltage drop
across it. Typical duration of this spike is 30 ns. At the same time, the OUT2 pin (in the example of Figure 3)
3/39
AN1625 APPLICATION NOTE
sees a voltage above VS, due to voltage drop across the high-side (integrated) freewheeling diode, as the current reverses direction and flows into the bulk capacitor. It turns out that the highest differential voltage is observed between two OUT pins when a phase change turns a high-side off during an off-time, and this must
always be kept below 60 V [2].
Figure 3. Currents and voltages if a phase change turns a high-side off during off-time.
Current starts
V
*I
S
PCB Parasit ic
Inductance
flowing in the
third half bridge
Bulk
Capacitor
Equivalent
Circuit
R
SENSE
*I+V
ESR
ESL
F(Diode)
PCB Parasitic
Inductance
R
SENSE
on-timeoff-timeduring of f-time
a phase change can occur
Figure 4 shows the voltage waveforms at the OUT pins referring to a possible practical situation, with a peak
output current of 2.8 A , V
= 52 V, R
S
= 0.33 Ω, TJ = 25 °C (approxim ately) and a good P CB layout. Below
SENSE
ground spike amplitude is -2.64 V for one output; the other OUT pin is at about 55 V. In these conditions, total
differential voltage reaches almost 60 V, which is the absolute maximum rating for the DMOS. Keeping differential voltage between two Output pins within rated values is a must that can be accomplished with proper selection of Bulk capacitor value and equivalent series resistance (ESR), accordi ng to current peaks and adopting
good layout practices to minimize PCB parasitic inductances (see below) [2].
Figure 4. Voltage at the two outputs if a phase change turns a high-side off during off-time.
OUT1
OUT2
SENSE
4/39
AN1625 APPLICATION NOTE
2.3 Choosing the Bulk Capacitor
Since the bulk capacitor, placed between VS and GND pins, is charged and discharged during IC operation, its
AC current capability must be greater than the r.m.s. value of the charge/discharge current. This current flows
from the capacitor to the IC during the on-time (t
power supply during off-time) to the capacitor during the off-time (t
into the bulk capacitor depends on peak output current, output current ripple, switching frequency, duty-cycle.
It also depends on power supply characteristics. A power supply with poor high frequency performances (or
long, inductive connecti ons to the IC) will cause the bulk c apacitor to be recharged sl owly: the higher the current
control switching frequency, the higher the current ripple in the capacitor; r.m.s. current in the capacitor, however, does not exceed the r.m.s. output current. Bulk capac itor value ( C) and the ESR determine the amount of
voltage ripple on the c apacitor itself and on the IC. Neglecting the output current rippl e and assuming tha t during
the on-time the capacitor is not recharged by the power supply, the voltage at the end of the on-time is
VSI
) and from the IC (during some phase changes; from the
ON
). The r.m.s. value of the current flowing
OFF
t
ESR
⋅–
OUT
-------- -+
ON
C
where I
is the output current. Usually (if C>100 µF) the capacitance role is much less than the ESR, then
OUT
supply voltage ripple can be estimated as
ESR⋅
I
OUT
For Example, if a max imum ri pple of 500 mV i s all owed and I
0.5V
------------
ESR
2A
Note that additional ripple is due to parasitic inductances on V
= 2 A, the capac itor E SR s hould be lower than
OUT
250mΩ=<
PCB tracks (see Voltage Ratings and Operating
S
Range section).
Actually, current sunk by V
and VSB pins of the device is subject to higher peaks due to reverse recovery
SA
charge of internal freewheeling diodes. Duration of these peaks is, tough, very short (100÷200 ns) and can be
filtered using a small value (100÷20 0 nF), good quality ceramic capaci tor, connected as close as possible to the
V
, VSB and GND pins of the IC. Bulk capacitor will be chosen with maximum operating voltage 25% greater
SA
than the maximum supply voltage, considering als o power supply toler ances . For exa mple, w ith a 48 V nomi nal
power supply, with 5% tolerance, maximum voltage is 50.4 V, then operating voltage for the capacitor should
be at least 63 V.
2.4 Layout Considerations
Working with devices that combine high power switches and control logic in the same IC careful attention has
to be paid to the PCB lay out. In extreme cases, Power DMOS commutation can i nduce nois es that could c ause
improper operation in the logic section of the device. Noise can be radiated by high dv/dt nodes or high di/dt
paths, or conducted through G ND or Supply connectio ns. Logic connec tions, es pecial ly hi gh-i mpedance nodes
(actually all logic inputs, see further), must be kept far from switching nodes and paths. With the L6235, in particular, external components for the charge pump circuitry should be connected together through short paths,
since these components are subject to voltage and current switching at relatively high frequency (600 kHz). Primary mean in minimizing conducted noise is working on a good GND layout (see Figure 5).
5/39
AN1625 APPLICATION NOTE
3
-
Figure 5. Typ ic a l App li ca ti on and Layout suggest io ns.
Phase
Brushless
DC Motor
D1
C5
R4
D2
C8
V
CP
SA VSB
SENSE
A
SENSE
B
R5
C6
C7
+
VS = 8 ÷ 52 V
-
GND GND
GND GND
C4
+
Logic Supply
3.3 ÷ 5 V
-
µC
or
Custom Logic
V
= 0 ÷1V
ref
3
V
BOOT
L6235
C3
R3
RC
PUL SE
OUT
OUT1 OUT
2
H1
H2
H3
FWD/REV
BRAKE
TACHO
DIAG
R1
EN
V
ref RCOFF
C1
C2
R2
High cur rent GND tracks (i .e. the trac ks con nected to the sens ing r esistor) m ust be c onnecte d dire ctly to the ne gative terminal of the bulk capacitor. A good quality, high-frequency bypass capacitor is also required (typically a
100 nF÷200 nF ceramic would suffice), since electrolytic capacitors show a poor high frequency performance.
Both bulk electrolytic and high frequency bypass capacitors have to be connected with short tracks to V
SA
, V
SB
and GND . On the L62 35 GND pins are th e Logic GND, sinc e only the q uiescent curren t flow s throu gh them . Logic
GND and Power GND should be connected together in a single point, the bulk capacitor, to keep noise in the
Power GND from affecting Logic GND. Specific care should be paid layouting the path from the SENSE pins
through the sen sing r esistor to the negative termin al of the bulk ca pacitor (P ower Ground) . These tracks mus t be
as short as possible in order to minimize parasitic inductances that can cause dangerous voltage spikes on
SENSE and OUT pins (see the Voltage Ratings and Operating Range section); for the same reason the capacitors on V
section for inf ormat ion on selec ting the sens e resis tors. Tr aces th at connect to V
, VSB and GND pi ns sho uld be ver y close to the GN D and sup ply pin s. Refe r to the Sens ing R esisto rs
SA
, VSB, SENSEA, SENSEB, and
SA
the three OUT pins must be d esi gne d w ith a dequ ate w id th, s inc e hig h cu rr ents ar e fl owing through the se tra ces ,
and layer ch anges sh ould be avoide d. Should a lay er ch ange prove necess ary, m ultiple an d large via holes have
to be used. A wide GND copper area can be used to improve power dissipation for the device.
Figure 6 shows two typical situations that must be avoided. An important consideration about the location of the
bulk capacitor is the ability to absorb the inductive energy from the load, without allowing the supply voltage to
exceed the maximum rating. The diode shown in Figure 6 prevents the recirculation current from reaching the
capacitors and will res ult in a high voltage on the IC pins th at can destroy the device. H aving a switch or a power
connection that can dis connect the c apacitors from the IC, w hile there is stil l c ur rent in the motor, will a lso result
in a high voltage transient since there is no capacitance to absorb the recirculation current.
6/39
AN1625 APPLICATION NOTE
Figure 6. Two situations that must be avoided.
DON’T put a diode here!
Recircul ating c urrent c annot flow into the
bulk capac itor and caus es a high voltage
spike that can dest roy the IC.
+
C7
VS = 8 ÷ 52 V
L6235
GND
V
SA VSB
SENSE
A
SENSE
B
R5
C6
GND
GND
GND
-
DON’T conne ct the Logic GND here
Voltage dro p due t o c urrent in s ens e
path can disturb logic GND.
2.5 Sensing Resistor
Motor winding current flows through the sensing resistor, causing a voltage drop that is used, by the logic, to
control the peak value of the load current. Two issues must be taken into account when choosing the R
value:
■ The sensing resistor dissipates energy and provides dangerous negative voltages on the SENSE pins
during the current recirculation. For this reason the resistance of this component should be kept low.
■ The voltage drop across R
parator. The lower is the R
SENSE
SENSE
to the input offset of the current sense comparator: too small values of R
A good compromise is calculating the sensi ng resistor value so that the voltage drop , corresponding to the peak
current in the load (Ipeak), is about 0.5 V: R
It should be clear that sensing resistor must absolutely be non-inductive type in order to avoid dangerous negative spikes on SENSE pins. Wire wounded resistors cannot be used here, while Metallic film resistors are recommended for their high peak current capability and low inductance. For the same reason the connections
between the SENSE pins, C6, C7, V
(see also the Layout Considerations section).
SENSE
is compared to the reference voltage (on Vref pin) by the internal com-
value, the higher is the peak current error due to noise on Vref pin and
must be avoided.
SENSE
= 0.5 V / Ipeak.
SENSE
, VSB and GND pins (see Figure 5) must be taken as short as possible
SA
The average power dissipated by the sensing resistor is:
PRI
D is the duty-cycle of the PWM current control, I
2
R
rms
SENSE
is the r.m.s. value of the load current.
rms
;
D⋅⋅≈
Nevertheless, sensing resistor power rating should be chosen taking into account the peak value of the dissipated power:
where I
is the peak value of the load current.
pk
P
2
I
R
pk
R
⋅≈
SENSE
,
Using multiple resistors in parallel will help obtaining the required power rating with standard resistors, and re-
7/39
AN1625 APPLICATION NOTE
duce the inductance.
R
The following table shows R
tolerance reflects on the peak current error: 1% resistors should be preferred.
SENSE
recommended values (to have 0.5V drop on it) and power ratings for typical
SENSE
examples of current peak values.
I
pk
0.510.25
10.50.52 X 1Ω, 0.25W paralleled
1.50.330.753 X 1Ω, 0.25W paralleled
20.2514 X 1Ω, 0.25W paralleled
R
SENSE
Value
[Ω]
R
SENSE
Power Rating
[W]
Alternatives
2.6 Charge pump external components
An internal oscillator, with its output at CP pin, switches from GND to 10 V with a typical frequency of 600 kHz
(see Figure 7).
Figure 7. Charge Pump .
VS + 10 V - VD1 - V
V
BO OT
D2
D1
C5
R4
CP
VS + 10 V - V
D2
V
SA VSB
D1
V
S
- V
D1
f = 600 kHz
C8
10 V
R
R
DS(O N)
DS(ON)
= 70Ω
= 70Ω
Charge Pum p
Oscillator
10 V
5 V
10 V
f =kHz
600
To High-Side
Gate Drivers
L6235
When the oscillator output is at ground, C5 is charged by VS through D2. When it rises to 10 V, D2 is reverse
biased and the charge flows from C5 to C8 through D1, so the V
imum voltage of V
With a differential voltage between V
current drawn by the V
+ 10 V - VD1 - VD2, which supplies the high-side gate drivers.
S
pin is 1.85mA.
BOOT
and V
S
of about 9V and the bridges switching at 50 kHz, the typical
BOOT
Resistor R4 is added to r educe the maximum current in the exter nal components and to reduce the slew rate of
the rising and falling edges of the voltage at the CP pin, in order to minimize interferences with the rest of the
circuit. For the same reason car e must be taken in realiz ing the PC B layout of R 4, C5, D1, D2 connections ( see
also the Layout Considerations section). Recommended values for the charge pump circuitry are:
Due to the high charge pump frequency, fast diodes are required. Connecting the cold side of the bulk capacitor
(C8) to V
= 100
instea d of GND the ave rage cu rre nt in the ex ter nal di odes during operati on is le ss tha n 10 mA (with R4
S
Ω
); at star t up (w h en VS is provided t o the IC) is less than 200 mA while the reverse voltage is about 10 V
in all co nd iti on s. 1N 41 48 dio de s withstand about 200 mA DC (1 A pea k ), and the max i mu m reverse vo lta ge is 75
V, so they should fit for the majority of applications.
2.7 Sharing the Charge Pump Circuitry
If more than one device is used in the applic ation, it's possible to use the char ge pump from one L6235 to suppl y
the V
Figure 8. A 100 nF capacitor (C8) should be connected to the V
Supply voltage pins (V
pins of several ICs. The unused CP pins on the slaved devices are left unconnected, as shown in
BOOT
) of the devices sharing the charge pump must be connected together.
S
pin of each device.
BOOT
The higher the number of devices sharing the same charge pump, the lower will be the differential volt age available for gate drive (V
- VS), causing a higher R
BOOT
for the high side DMOS, so higher dissipating po wer.
DS(ON)
In this case it's recommended to omit the resistor on the CP pin, obtaining a higher current capability of the
charge pump circuitry.
Better performance can also be obtained using a 33 nF capacitor for C5 and using schottky diodes (for example
BAT47).
Sharing the same charge pump ci rcuitr y fo r mor e than 3÷4 devi ces is not recommended, sinc e it wil l reduce the
V
voltage increasing the high-side MOS on-resistance and thus power dissipation.
BOOT
Figure 8. Sharing the charge pum p circuitry.
To other Devices
V
BO OT
To High-Side
Gate Drivers
V
V
SA
CP
SB
L6235
C18 = 100 nF
D2 = BAT47
CP
V
SA VSB
C8 = 100nF
V
BOOT
To High-Side
Gate Drivers
D1 = BAT47
C5 = 33nF
L6235
9/39
AN1625 APPLICATION NOTE
2.8 Reference Voltage for PWM Current Control
The device has an analog input, Vref, connected to the internal sense comparator, to control the peak value of
the motor current through the integrated PWM circuitry. A fixed reference voltage can be easily obtained through
a resistive divider from an available 5 V voltage rail (maybe the one supplying the µC or the rest of the application) and GND.
A very simple way to obtain a variable voltage without using a DAC is to low-pass filter a PWM output of a µC
(see Figure 9).
Figure 9. Obt ain in g a va ri abl e v ol ta ge t hro ugh a PWM ou t put of a µC .
PWM Output
of a µC
R
LP
R
DIV
GND
V
ref
C
LP
Assuming that the PWM output swings from 0 to 5V, the resulting average voltage will be
5V DµCR
⋅⋅
-----------------------------------------=
RLPR
where D
V
ref
is the duty-cycle of the PWM output of the µC.
µC
Assuming that the µC output impedance is lower than 1k
DIV
+
DIV
Ω,
with RLP = 56kΩ, R
= 15kΩ, CLP = 10nF and a
DIV
µC PWM switching fr om 0 to 5V at 100kHz , the l ow pass fi lter tim e consta nt is about 0.12 ms an d the remai ning
ripple on the V
voltage will be about 20 mV. Using higher values for RLP, R
ref
and CLP will reduce the ripple,
DIV
but the reference voltage will tak e more time to vary after changing the duty -cycle of the µC PWM, an d too high
values of R
As sensing resistor value is typically kept small, a small noise on V
will also incr ease the impedance of the V
LP
net at low frequencies, causi ng a poor noise immuni ty.
ref
input pins might cause a considerable error
ref
in the output current. It's then recommended to decouple this pin with a ceramic capacitor of some tens of nF,
placed very close to Vref and GND pins. Note that Vref pin cannot be left unconnected, while, if connected to
GND, zero current is not guaranteed due to voltage offset in the sense comparator. The best way to cut down
(IC) power consumpti on and clear the l oad current is pul ling down the EN pin. With very small refer ence voltage,
PWM integrated circuitry can loose control of the current due to the minimum allowed duration of t
(see the
ON
Programmable off-time Monostable section).
10/39
AN1625 APPLICATION NOTE
2.9 Input Logi c pin s
H1, H2, H3, FWD/REV, BRAKE, ENABLE, are CMOS/TTL compatible logic input pins. The input comparator
has been realized with hysteresis to ensur e the required noise immunity . Typical val ues for turn-on and turn-off
thresholds are V
electro-static discharge), and can be directly connected to the logic outputs of a µC; a series resistor is generally not
recommended, as it could hel p induct ed noise to dist urb the input s. All logic pi ns enfor ce a specifi c behavior and cannot be left unconnected. If connected to the DIAG pin, EN pin must be driven through a series resi stor of 2.2 k
imum (for 5 V logic), to allow the voltage at the pin to be pulled below the turn-off threshold (see below).
Figure 10. Logic input pins.
= 1.8 V and V
TH(ON)
TH(OFF)
= 1.3 V.
H1, H2 H3
FWD/REV, BRAKE
ENABLE
Pins are ESD protected (see Figure 10) (2kV human-body
5 V
,
ESD
Protection
,
Ω
min-
2.10DIAG pin
DIAG pin is an open-drain output pul led to GND in case of ov ercurrent or over temperatur e conditions. Connecting this pin to EN will allow the internal open drain to disable all the power DMOS of the L6235, provided that
the EN pin is driven through a resistor (see Input Logic pins).
A capacitor (C1 in Figure 5 and Figure 11) conne cted between EN and DIAG pins and GND is als o recommended, to reduce the r.m.s. value of the output current when overcurrent conditions persist (see Over Current Protection section).
Figure 11. DIAG pin.
µC or Logic
Output
R1
C1
EN
DIAG
11/39
AN1625 APPLICATION NOTE
2.11Programma ble off-time Monostable
The L6235 includes a constant off time PWM Current Controller. The current control circuit senses the bridge
current by sensing the voltage drop across an external sense resistor connected between the source of the
three lower power MOS transistors and ground, as shown in Figure 12. As the current in the motor increases
the voltage across the sense r esistor incr eases pr oportionall y. When the voltage drop across the s ense r es istor
becomes greater than the voltage at the reference input pin VREF the sense comparator triggers the
monostable switching the bridge off. The power MO S re main off for the time set by the monos table and the motor current recirculates ar ound the upper half of the bridge in S low Decay Mode as described in the next sec tion.
When the monostable times out, the bridge will again turn on. Since the internal dead time, used to prevent
cross conduction in the bridge, delays the turn on of the power MOS, the effective Off Time t
the monostable time plus the dead time.
Figure 13 shows the typical operating waveforms of the output current, the voltage drop across the sensing resistor, the pin RC vol tage and the status of the bridge. More d etails regarding the S ynchronous Rectificati on and
the output stage configuration are included in the next section.
Immediately after the Power MOS turn on, a high peak current flows through the sense resistor due to the reverse recovery of the freewheeling diodes. The L6235 provides a 1µs Blanking Time t
BLANK
comparator output so that the current spike cannot prematurely retrigger the monostable.
is the sum of
OFF
that inhibits the
Figure 12. PWM Current Controller Simplified Schematic
VS
B
TO GATE
LOGIC
5mA
S
(0)(1)
5V
RCOFF
C
OFF
R
OFF
Q
R
-
+
2.5V
BLANKING TIME
MONOST ABLE
1µs
MONOST ABLE
SET
COMP ARATOR
BLANKER
SENSE
FROM THE
LOW-SIDE
GATE DRIVERS
DRIVERS
+
DEAD TIME
+
-
VREF
R
SENSE
SENSE
DRIVERS
+
DEAD TIME
B
SENSE
DRIVERS
+
DEAD TIME
A
D02IN1380
VS
A
VS
OUT
OUT
OUT
2
3
1
12/39
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