MOTOROLA ‘Order this document by ANI3211 SEMICONDUCTOR Sac APPLICATION NOTE AN1321 Brushless DC Motor Drive Incorporates Small Outline Integrated Circuit Packaged MOSFETs Prepared by: Wayne Chavez Discrete Applicaions Engineering INTRODUCTION Miniaturzation is the trend in vitually all consumer lection products, Consider te market for computer hard ‘isk drives where disk size has progressed from 8°. 5.25", 35°, 2.8" and now to the 1.3" dre. Product miniatunzaton demands smaller components, including semiconductors. ‘Surface mount technology is one solution that contributes to this trend, t enables the placement of semiconductor components on both sides of a printed circut board in a ‘smaller area, increasing component density and resulting in 4 small overall product. ‘Surface mount components now include power MOSFETs in SOIC (Small Outline integrated Circuit surface ‘mount packages. Those very same packages that contain SURFACE MOUNT loge or other integrated circuits now house medium power MOSFETs. These devices are applicable where space Is at a premium and extra power capabiliy is necessary Inauerive switcning, small motor drives and hammer drivers are typical applications. In particular, the MMDF2COSE, an ‘80-16 packaged complementary nall-bridgo, is relatively ‘eagy to implement into a motor drive system. ‘This application note deseribes a brushless DC motor drive (BLOC) dasign simiar in size to those found in har ‘sk spindle motor drives. The system is parttioned into control, power, feedback and motor sections. Evaluation board, DEVB156 snown in Figure 1, resulted from the design and is described herein, nays Clea sts 3 sh ete Ct MOTOROLA DISCRETE APPLICATIONS Figure 1. DEVB156 Surface Mount Brushless DC Motor © voromcta mc 183 jive EVE & MOTOROLA naa REV‘SYSTEM DESCRIPTION A spindle motor dive consists of a brushless OC motor, control circuitry, power transistors and a feedback network, A ‘ypical system block diagram is chown below in Figure 2. euecTRoNe esse | TACHOMETER (yuo 2cose "V2ORIDGES care sais 1 iv RULES Dc MOTOR Wr AULEFECT SENSORS sxsorrou ff | CONROE) yeseow | 9BTOP ‘ecorron fg oro ecaorr0u ey URRENT SENSE Figure 2, System Block Diagram ‘The enti design is based upon the motor. The motor type dictates how t willbe driven and controled. inthis case, ‘the motors a Brushless DC type, known fr is reliable anc tong lasting performance. This motor must be commutated electronically thus requiing a fiy complex control schome. Fortunately, integrated circuits are available for driving Drushiess DC moturs. Givwn ie ruler positon, a contro IC performs the commutation sequencing function. In ation, the control IC regulates motor speed. Also included in the control portion of the system are features such as current limiting, fault detection and over-temporature shut down, “The power transistors are the electrical muscle of this system, Si transistors, one half-bridge per motor phase, are needed te spin the motor. The control IC’s output signals select the powar transistors to be tured on, which powers two motor windings at atime, thus commutating the motor. “The feedback network provides information regarding rotor position for commutation and speed control. Rotor position is sensed by three Halleffect sensors or by ‘sensorless techniques, These sonse signals are then fed back to the control IC where they are decoded to produce the next commutation sequence. The frequency of each sense signals drecty proportional tothe speed of the motor. Hence, the sense signals serve a dual purpose BLDC MOTOR APPLICATION A surface mount brushless DC motor drive was designed to demonstrate the functionaity of the MMOF2COSE, SOIC MOTOROLA 2 ‘complementary MOSFETS, in a closedioop motor control system. The Schematic and component layout are shown in Figutes 3 and 4, respectively. Control! Circuitry The MC33035 is an integrated circuit speciticaily designed or brushless DC motor control systems, The main function ofthe MC33096 isto decode signals from Hal-etlect sensors and generate logic signals to electronically ‘commutate the moter. These foie signals intemaly control sixoutbut 2. = s2 sre open collector outputs intended to dive the upper ha-ndge P-channel logs. The remaining three are totem pole outputs used to actively pulse width medulate (PWM) the N-channel MOSFETS. ‘Overcurrent setecton is another feature ofthe MC33036. “The MCO9095 has an internal comparator used for detecting ‘xcessive motor curtis, The motor current is sensed by the voltage developed across a current sense resistor, R11 |When the voltage reaches 100 mv, all bottom transistors are latched off and the FAULT pin goes tow until the next PWM cycle, ANT Is sized to limit the current at wo amps, Figure 5 demonstrates an overcurrent condition, This figure shows the motor current increasing atter applying a road en the motor shaft, Note that the FAULT pin goes iow When the 100 mY threshold is reached and stays low unt the next PWM cycle, Also notice that the current sense signal goes to zero since all the bottom transistors are of antsat5288 Figure 3. Brushless DC Motor Drive MOTOROLA antaa1‘The overcurrant comparator is very sensitive to transients. For this raason R10, R13 and C1 low pass filer the voltage across R11 beloce it reaches the comparator. ‘This prevents neige er treewhooing clove reverse recovery spikes from tipping the comparator. Ota “HELO : Eas: tae il « nal ee ee ae ain QoQ 0000 4 Sen O0:8 © ee gla) = 2 1 | rer “4 oN ek | ae ‘ox0| o QO aa Sarr ns gi 8 cote > oer fan e 90 sy geese ° MOTOROLA DISCRETE APPLICATIONS ° Figure 4, Component Layout ‘Also on-chip isa high performance error ampiter intended for closed-loop speed control. The error ampitier is used to filer and butler a frequency moduiated signal proportional to the speed. R17, R22, C4 and the error ‘amplifer make up this fiter network. The fitered voltage {a thon used to eat the PWM duty eyela. Again refering to Figure 5, aote that as a load was presented to the motor shatt, the duty cycle became very hich to regulate speed. Under-voliage lockout provided by the MC33035 avoids possible power transistor abuse by disabling the output stage fat supply votlages less than 9.1 V. This ensures that the transistors wil not be under driven Power Transistors “The transistors easiest to design into alow voltage motor drive are complementary MOSFET hal-bridges. The MMOFZCOSE contains such a configuration of MOSFETs packaged in a standard SO-16 (small outine - 16 pin) package, “The question now arses as to how much power can the MMDF2COSE dissipate, With minimum recommended pad sizes, the MMOF2COSE can dissipate approximately 1.5 watts gven a 25°C ambient temperature. Increasing pad sizes and incorporating a PCB matevial with ower thermal Iesiblance increnses the power dissipation rating. To inerease the power capably of the conventional SOIC package, a special leagtrame copper design was employed. EE MOTOROLA sv ‘soul Figure 6. Overcurrent Condition ‘The common dain configuration of the MOSFETS allows both of them to share a common lead frame, 28 shown in Figure 6, The lead frame then connects to multiple extemal leads giving ten thermal paths out of the package. 1 6 ve eS v+ output REEL asl ourPuT oureur SEI OUTPUT oureut === ovreut fa Ser ourpur C= | == OUTPUT oureur Ge eal =o output No eno 8 ° Figure 6. MMOFZCOSE Lead Frame ‘The MMDF2COSE has an on-resistance, Ros(on). fang ‘of 300 m2, maximum, per hall-briage lag at Vis = 10 ¥. Each MOSFET also has a 80 V breakdown voltage rating and a continuous current raing of 2 amos. Of the dynamic characteristics, the most important In a motor drive isthe ‘Commutating Safe Operating Area (CSOA) The challenging part in implementing MOSFET hall-bridges in a motor drive appicaion is efficiently desnapping the freewheeling diodes. In other words. one anr32tmust soften the reverse recovery characteristics of the P-channel intrinsic drin-to-source diodes without incurring Unacceptable switching losses. This is done by employing 1 gate crve impedance strategy. The gate impodances RI. Re and AG ate optimized to soften the abrupt reverse Tecovery in their corresponding halF-bridge ‘Sottening sina saan is accomplished by Keening dis manageable and allowing an optimal amount of “shootthrough current o pass. Shoot-through current results from dvidt’s coupling through the P-channel drain-gate capacitance to the impedances, F2 and R3. The aviat's fare generated by the bottom pulse width modulated transistors. A voltage develops from the P-channel gate-to-source partially tuning it on. The resuiting ‘modulated MOSFET drain currants dominates by P-channel ‘conduction and masks the abrupt recovery af the diode, 2 nd AS deter Uie magnitude of shoot through ourront ‘and the ime it takes forit to decay, while A1 sets the positive dict of revarse recovery. Figure 7 demonstrates a softened reverse recovery wave form. It is interesting to note that the peak curentin thie wave form is approximately 3.3 amps, but does not trip the overcurrent detect comparator because of the overcurrent iow pass fier. ‘ona Figure 7, Reverse Recovery Wavetorm Reverse recovery is another source of extremely high id's. Any stray inductance in the high current paths (generate voltage spikes and unwanted noise, Reverse Fovevery le also a source af alacttamagnaic intererance. For these reasons itis important to soften the diode snap, keep high current loops small and utlize a single grounding point for the IC and other low current circuit. Feedback ‘The sources of feedback information are three evenly spaced Hal-effect sensors. As mentioned previously, tne Halleffects give information regarding rotor position and motor speed. As a magnetic ple, rom a magnet externally placed on the motor shatt, passes by a Hall-ofect sensor the sensor outputs @ positive pulse, Therefore, the rotor positon is known by the combination of the three sensor signals For speed information, a companion IC, MC33099. is. used. Atposttve and negative transitions of each Hali-efect sensor, the MC33039 generates a positive pulse of fixed duration set by R12 and C2, as shown in Figure 8. As the ‘motor tums faster, the MC33039 output pulses become Closer together and the average voltage over each penod (UT ‘<_< Const Speed Teasing S508 Figure 8, MC33039 Output Signal ‘Therefore, the avorage voltage of the MC35099 output is constant when the speed is regulated. As mentioned previously, these pulses are averaged, or fitered, by the 1MC39036 error ampitior to set the PWM duty cycle. Tho ret etfect is closed-loop speed contr IZ and C2 set the puse duration to 900us, which ‘corresponds to a maximum motor speed of 5500 rpm. Speed Feguiation below this Ievel is accomplished by adjusting tnm potentiometer R18. This adjusts the average regulated ‘voltage and thus sets the speed. EVALUATION BOARD DESCRIPTION DEVBI56 was oreated 10 demonstrate the use of the MMDF2COSE devices in a surface mount motor drive application. The folowing features are designe into the evaluation oars: Overcurrent limiting ‘Speed Control Fault incication ForwardiRiaverse capabiity 60° and 120° phase sensing capability EnableDisable control, Under voltage lock out (Over temperature shut down ‘Overcurrent Limiting Overcurrent is observable at motor startup by monitoring the fault output of the control IC. At startup, atypical 25° disk drive spindle motor draws 4 to 5 amps and, at steady ‘operation, draws approximately 500 mA. Due to the long time constant in tha current iit low pass iter, the current in the motor reaches lavels over 2 amps. This helps the ‘motor come up to speed more rapidly. Oe anra21 MOTOROLA $‘Speed Control For versatility, two different methods of programming speed are available, The first i provided in the design of the evaluation board. The speed of the motor is adjusted to the desited level by turning the trim potentiometer marked SPEED. Clockwise adjustmont increases the speed, The ‘S000nG option Is W apply 2 vellaye signe! 19 the ANALOG INterminal, An applied signal at tis terminal can range from Ground to 4.5 V where the later corresponds to full speed. To select between the two modes, jumper J1, must be positioned appropriately. Connecting pins two and three with ‘it enables the tim pot to set the speed. Connecting pias fone and two enables the ANALOG IN terminal, NOTE: Jumper J1 should not be lett open. Fault Indication ‘Tne fault indicators simply an LED labeled FAULT. The LED lights up whan any or ll of these conations are present overcurrent, invalid Halleffect sequence, undervettage, overtemperatute or cisable, The fault signal is a good slagnostic indicator and can be interfaced with other ogic systems. Forward/Reverse ‘The terminal labeled FWDIREV gives the option of édirectional motor operation. Leaving the terminal open wil resutt in forward operation. By grounding or applying 2 logic level ‘tow’, the motor will reverse direction. MOTOROLA Enable/Disable ‘A switch labeled ENABLE is available on the board to sable the motor without turning the power off. The motor is enabled when the switch i in the high position ang ‘disabled in the low postion 60° and 120° Phace Sencing ‘The versatilty of the MC3G035 allows it 10 be used with diferent types of motors. The swite labeled 60/120 allows the board to be used with motors possessing either 60° oF 420° sensor spacing. 60° sensing is enabled when the ‘switch isin the low postion, Power and Motor Connections, The evaluation board operates from a 12 V source. The power connections are inhale «19 and GNO and are located fon the right side of the board. Al motor connections, inclucing Hall-effct sensor connections are on the left side fof the board. Terminals A OUT, B OUT and C OUT connect the three motor windings to the MOSFET transistors, Terminals A SENSE, B SENSE and C SENSE are trom the Hal-etiect sensors. I is important that each sensor input corresponds to an output terminal {A OUT corresponds to [A SENSE). The VAEF terminal is used to power the Hall sensors, and the GNO terminalis the return. Taoie 1 presents a list of ll the devices used in this design. anis2iTable 1, Parts List tannin Gomntty] Deseo a a 7 [bana Castor a Ta zea Gapcir cacaer 3] oF Geos s oF tose oF [aio scape |i apn | Snare CONES ee Pasa | evvaoan cone | seemnbet eres Pax Conea | TO cont TT eternal comecor Faxoomea | 00 Tue 7 8a ter Moura | ware Tae 2 [0 Fanasone | P00 m 1] oor soer 1,02,03 ee Complementary 1/2 Bridge ‘Motorola MMDF2CO5E ALERT 3] 10 Rite rarer 3 [10 peste TaRaRE 3 | sso Rear rian 2 [in Fesser amr 1 [oes raw Reva oe aia 2 [oon fase wre TS pest ms 1 [aon Rene 8 TT 2k Passnr a7 Two Fer fer er Fa DAE au 0 2 | 10 reer ma 7 [iw ress Swrve 2 sP0T sch a we iaore or 1 wes a Z To Tiiesens vieia— wosenosow [Al capactor an resistor are eulace moun size 1206 except those marked wit an asterisk) Surface mount technology is responsible for increasing Printed Circut Board component density thus leading to Devices such as the NMDF2COSE make this miniaturization possible. In action toits small siz, this device offers the advantages of a mare increased _ miniaturization. aniazy CONCLUSION simplistic gate drive design and Increased power handing ceapabiliy. Their application to a 12 V brushless DC motor drive demonstrates the minimum number of gate dive ‘components necessary, tus Kegping the part count down and precious board space conserved. 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