Download Stellaris RDK-BDC24 Brushed DC Motor Control Module User`s

Stellaris® RDK-BDC24 Brushed DC Motor
Control Module
User ’s Manual
RDK-BDC24 -UM-0 4
Co pyrigh t © 2 010– 201 2 Te xas In strumen ts
Copyright
Copyright © 2010–2012 Texas Instruments, Inc. All rights reserved. Stellaris and StellarisWare are registered trademarks of Texas Instruments.
ARM and Thumb are registered trademarks, and Cortex is a trademark of ARM Limited. Other names and brands may be claimed as the property
of others.
Texas Instruments
108 Wild Basin, Suite 350
Austin, TX 78746
http://www.ti.com/stellaris
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January 4, 2012
Stellaris® Brushed DC Motor Control User’s Manual
Table of Contents
Chapter 1: Stellaris® Brushed DC Motor Control Reference Design Kit (RDK) Overview ........................ 7
Feature Summary ............................................................................................................................................... 8
Specification Overview ....................................................................................................................................... 8
Reference Design Kit Contents .......................................................................................................................... 9
Chapter 2: Using the Reference Design Kit ................................................................................................. 11
Important Information........................................................................................................................................ 11
Developing with the RDK.................................................................................................................................. 11
Power Supply Selection .................................................................................................................................... 11
Motor Selection ................................................................................................................................................. 12
Chapter 3: Firmware Updates and Debugging............................................................................................. 13
General Information .......................................................................................................................................... 13
Firmware Update Using RS232/CAN ............................................................................................................... 13
Firmware Update and Debugging Using JTAG/SWD ....................................................................................... 13
Chapter 4: Hardware Description .................................................................................................................. 15
System Description ........................................................................................................................................... 15
Key Hardware Components.............................................................................................................................. 15
Schematic Description ...................................................................................................................................... 15
Microcontroller, CAN, and I/O Interfaces (Schematic page 1) ...................................................................... 15
Output Stage and Power Supplies (Schematic page 2)................................................................................ 17
Texas Instruments’ Featured Parts................................................................................................................... 20
Appendix A: Schematics................................................................................................................................ 21
Appendix B: Board Drawing .......................................................................................................................... 24
Appendix C: Bill of Materials (BOM) ............................................................................................................. 25
January 4, 2012
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List of Figures
Figure 1-1.
Figure 1-2.
Figure 3-1.
Figure 3-2.
Figure 4-1.
Figure 4-2.
Figure 4-3.
Figure 4-4.
Figure B-1.
4
MDL-BDC24 Brushed DC Motor Control Module ............................................................................ 7
MDL-BDC24 Module Key Features (top view) ................................................................................ 9
Locating the JTAG/SWD Connector.............................................................................................. 13
Firmware Debugging Using JTAG/SWD ....................................................................................... 14
MDL-BDC24 Circuit Board ............................................................................................................ 15
MDL-BDC24 JTAG/SWD Connector............................................................................................. 16
Network Connector Pin Assignments............................................................................................ 17
Synchronous Rectification............................................................................................................. 19
Component Placement Plot........................................................................................................... 24
January 4, 2012
Stellaris® Brushed DC Motor Control User’s Manual
List of Tables
Table 2-1. Mabuchi RS-555PH-3255 Motor Specifications ............................................................................ 12
Table 4-1. Detailed List of Texas Instruments’ Featured Parts ...................................................................... 20
Table C-1. RDK-BDC24 Bill of Materials (BOM) ............................................................................................. 25
January 4, 2012
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January 4, 2012
C H A P T E R 1
Stellaris® Brushed DC Motor Control Reference
Design Kit (RDK) Overview
The RDK-BDC24 is a Stellaris reference design for speed control of 12 V and 24 V brushed DC
motors at up to 40 A continuous current. Features include high-performance CAN and RS232
networking as well as a rich set of control options and sensor interfaces, such as analog and
quadrature encoder interfaces.
High-frequency PWM enables the DC motor to run smoothly and quietly over a wide speed range.
The MDL-BDC24 uses highly optimized software and a powerful 32-bit Stellaris LM3S2616
microcontroller to implement open-loop speed control as well as closed-loop control of speed,
position, or motor current.
The Reference Design Kit (RDK-BDC24) contains an MDL-BDC24 motor control module as well
as additional hardware and software for evaluating RS232 communication. After evaluating the
RDK-BDC24, users may choose to either customize parts of the hardware and software design or
use the MDL-BDC24 without modification.
See the MDL-BDC24 board data sheet (available for download from http://www.ti.com/stellaris) for
complete technical specifications. In addition, the MDL-BDC24 Getting Started Guide
(GSG-MDL-BDC24) provides a step-by-step guide to wiring and using the module.
Figure 1-1.
January 4, 2012
MDL-BDC24 Brushed DC Motor Control Module
7
Stellaris® Brushed DC Motor Control Reference Design Kit (RDK) Overview
Feature Summary
The MDL-BDC24 control board provides the following features:
„
Controls brushed 12 V and 24 V DC motors up to 40 A continuous
„
Controller Area Network (CAN) interface at 1 Mbit/s
„
Industry-standard servo (PWM) speed input interface
„
RS232 to CAN bridge
„
Limit switch, encoder, and analog inputs
„
Fully enclosed module includes cooling fan
„
Flexible configuration options with simple source file modification
„
Easy to customize—full source code and design files available
Specification Overview
Key specifications of the MDL-BDC24 include:
„
Quiet control of brushed DC motors
– 15 kHz PWM frequency
„
Three options for Speed control
– Industry-standard R-C servo type (PWM) interface
– Controller Area Network (CAN) interface
– RS232 serial interface
„
CAN communication
– Multicast shared serial bus for connecting systems in electromagnetically noisy
environments
– 1M bits/s bit rate
– CAN protocol version 2.0 A/B
– Full configurability of module options
– Real-time monitoring of current, voltage, speed, and other parameters
– Firmware update
„
RS232 serial communication
– Bridges RS232 port to a CAN network
– Directly interfaces to a PC serial port or National Instruments cRIO
„
Status LED indicates Run, Direction, and Fault conditions
„
Motor brake/coast selector
„
Limit switch inputs for forward and reverse directions
„
Quadrature encoder input (QEI)
– Index input
– 5 V supply output to encoder
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January 4, 2012
Stellaris® Brushed DC Motor Control User’s Manual
„
Analog input
– Accepts 10 kΩ potentiometer or 0-3 V input
„
Screw terminals for all power wiring
„
Headers (0.1 inch pitch) for all control signals
For detailed specifications including electrical parameters, see the MDL-BDC24 data sheet.
Figure 1-2.
MDL-BDC24 Module Key Features (top view)
For power wiring use
12AWG Wire with # 6 ring
or spade terminals
Maintain 0.5 " clearance
around all vents
Motor output is not protected
against short- circuits.
From Power
Distribution
Module
(– ) In
Motor
Out
(– ) Motor
(+) In
(+) Motor
Mounting holes
3.50 " centers
User Switch
Maintain 0.5" clearance
around all vents
CAN Port
6P6C CAN/RS232 Port
Status LED
Limit switch inputs
Use hooks to prevent
wires shaking loose
Encoder Input
Analog input (0-3V)
Motor coast / brake jumper
Reference Design Kit Contents
The RDK-BDC24 contains everything needed to evaluate brushed DC motor control. The
RDK-BDC24 includes:
„
MDL-BDC24 motor control module
– Suitable for motors up to 24 V 40 A
– Uses a Stellaris LM3S2616 microcontroller
„
Mabuchi RS-555PH-3255 Brushed DC Motor
– 5000 RPM, 12 V, 3 A
„
Universal input wall power supply
– 12 V 1.25 A
January 4, 2012
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Stellaris® Brushed DC Motor Control Reference Design Kit (RDK) Overview
– Plug adaptors for US, UK, EU, and AUST
„
DB9S to 6P6C adapter
– Connects the MDL-BDC24 to a PC RS232 port
„
6P-6C modular cable 7-ft
– Use for RS232 or CAN connection
„
CAN terminator
– Plug-in 120-Ω terminator
„
Adapter cable for ARM JTAG/SWD fine-pitch header
– Texas Instruments Part ADA2
„
Reference design kit CD
– Complete documentation, including Quickstart and user’s guides
– LM Flash Programmer utility for firmware updates
– Complete source code, schematics, and PCB Gerber files
The source code can be modified and compiled using tools from Keil, IAR, CodeRed,
CodeSourcery, GCC, and Code Composer Studio.
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January 4, 2012
C H A P T E R 2
Using the Reference Design Kit
This chapter provides information about using the RDK-BDC24.
Important Information
WARNING – In addition to safety risks, other factors that may damage the control hardware, the
motor, and its load include improper configuration, wiring, or software. Minimize the risk of
damage by following these guidelines.
„
Always wear eye protection and use care when operating the motor.
„
Read this guide before connecting motors other than the motor included in the RDK. DC
motors may not be directly interchangeable and RDK parameter changes may be necessary
before the new motor will operate correctly.
„
Damage to the control board and motor can result from improper configuration, wiring, or
software.
Developing with the RDK
The recommended steps for using the RDK are:
„
Follow the README First document included on the kit CD. The README FIrst document
will help you get the RS-555 motor up and running using the BDC-COMM Windows
application in just minutes. It also contains important safety information that you should read
before using the RDK.
„
Use the BDC-COMM to evaluate and optimize target motor operation. Once the module is
installed in the end application, use the BDC-COMM to configure and monitor motor operation.
Using RS232, the BDC-COMM gives real-time access to a range of operating parameters.
The MDL-BDC24 Getting Started Guide covers module setup and use in customer
applications.
„
Customize and integrate the software and/or hardware to suit an end application. This
user’s manual and the RDK-BDC24 Firmware Development Package User’s Guide are two
important references for completing hardware and software modifications. New software can
be programmed in the MDL-BDC24 using either BDC-COMM, or using a JTAG/SWD debug
interface.
Power Supply Selection
The MDL-BDC24 is designed primarily for use with 12 V or 24 V sealed lead-acid batteries. Other
power sources may be used as long as the MDL-BDC24’s voltage range is not exceeded under
any condition.
There are two important considerations when selecting a power supply. The first is specifying a
supply that can supply the starting current of the motor. Even unloaded motors may have a starting
current that can momentarily exceed 60 A. Some switching power supplies will shut down very
January 4, 2012
11
Using the Reference Design Kit
quickly when starting a brushed DC motor. The power supply does not need to maintain regulation
during start, but it must ensure that the supply voltage remains above the under-voltage limit.
The second consideration is how the power supply handles back-EMF and regeneration currents.
During rapid deceleration of loads with high inertia, the motor acts as a generator. This current is
rectified by the MDL-BDC24 back into the bus capacitor. As the capacitor charges, the voltage at
the supply terminals may increase. It is important that the power supply can handle this
momentary condition without entering a fault condition. The power supply must also present
sufficiently low impedance so that the MDL-BDC24’s voltage rating is not exceeded. A sealed
lead acid battery easily meets these requirements.
NOTE: The MDL-BDC24 does not have reverse polarity input protection.
Motor Selection
The MDL-BDC24 operates 12 V to 24 V brushed DC motors. Typical motors include model
BI802-001A from CIM and model RS-555PH-3255 from Mabuchi (see Table 2-1 for motor
specifications). Some very small DC motors or motors in lightly loaded applications may have a
limited useful speed range when controlled with PWM based voltage controls.
The MDL-BDC24 can also drive resistive loads with some de-rating to allow for increased ripple
current inside the module. See the MDL-BDC24 board data sheet for full specifications.
Table 2-1. Mabuchi RS-555PH-3255 Motor Specifications
Parameter
Value
Units
Speed
3953
RPM
Current
1.244
A
Power
7.139
W
Torque
17.25
mMm
Speed
2325
RPM
Current
3.627
A
Power
14
W
Torque
57.5
mMm
No load speed
4650
RPM
No load current
0.223
A
At maximum efficiency
At maximum power
General characteristics
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January 4, 2012
C H A P T E R 3
Firmware Updates and Debugging
The MDL-BDC24 supports two methods for updating the firmware resident in the LM3S2616
microcontroller. The primary method, commonly used for field updates, uses the CAN or RS232
interface and a Flash-resident boot loader for firmware transfer. During actual firmware
development, direct access and debug capability is preferable. The MDL-BDC24 included in the
RDK has a JTAG/SWD connector installed for this purpose.
General Information
StellarisWare firmware revisions are referenced using four-digit numbers that increase with new
releases, but are not necessarily contiguous (that is, numbers may be skipped).
The flash memory region between 0x0000 and 0x07FF contains a CAN/RS232 boot loader. The
main firmware image should be loaded at 0x0800.
Firmware Update Using RS232/CAN
The MDL-BDC24 firmware can be updated over RS232 or CAN using the BDC-COMM utility and
the cables included in the reference design kit. See the MDL-BDC24 Getting Started Guide for
step-by-step instructions.
Firmware Update and Debugging Using JTAG/SWD
The MDL-BDC24 included in the RDK has a 2 x 5 fine-pitch header installed for firmware
programming and debugging using JTAG/SWD. JTAG is a four-wire interface. SWD is a
high-performance, two-wire interface with similar capabilities. Figure 3-1 on page 13 shows how to
locate the JTAG/SWD connector.
Figure 3-1.
Locating the JTAG/SWD Connector
JTAG /SWD Connector
Pin 1 is at this end
January 4, 2012
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Firmware Updates and Debugging
When using the JTAG/SWD cable, pay special attention to the location of pin 1 on the connector.
When inserted correctly, the cable runs back across the bottom of the case, covering the
rectangular inset. See Chapter 4, “Hardware Description,” for additional information on the JTAG/
SWD connector.
Any Stellaris evaluation boards can be used as a low cost In-circuit Debug Interface (ICDI) for both
programming and debugging. The ICDI circuit is compatible with LM Flash Programmer as well as
leading development tools for ARM® Cortex™-M3. Evaluation versions for several tools are
available from www.ti.com/stellaris.
Figure 3-2.
Firmware Debugging Using JTAG/SWD
Ribbon cabl e
ADA2
10-pin to 20-pin
Adapter Cable
PC running LMFlash
Programmer or o ther
De velop ment tool
USB
14
Any Stell aris® Eva luation
Board. No softwa re required.
January 4, 2012
C H A P T E R 4
Hardware Description
The MDL-BDC24 motor control module uses a highly integrated Stellaris LM3S2616
microcontroller to handle PWM synthesis, analog sensing, and the CAN/RS232 interface. Only a
few additional ICs are necessary to complete the design. The entire circuit is built on a simple
two-layer printed circuit board. All design files are provided on the RDK CD.
System Description
A unique aspect of the MDL-BDC24 design is the integrated CAN interface and low-cost,
fan-cooled MOSFET array that handles high current in a small form-factor. The motor control
consists of an H-bridge arrangement which is driven by fixed-frequency PWM signals.
Key Hardware Components
Figure 4-1 shows the MDL-BDC24 circuit board with the enclosure and cooling fan removed.
Figure 4-1.
MDL-BDC24 Circuit Board
DC bus capacitor
Current sense circuit
MOSFET
H- bridge
JTAG/ SWD connector
( other side)
Switching power
supply
Stellaris® LM3S 2616
Microcontroller
RS232 transceiver
User switch
Servo/ PWM input
optocoupler
16 MHz crystal
Gate driver
6P6C CAN /RS232
connector
Status LED
CAN transceiver
Schematic Description
Microcontroller, CAN, and I/O Interfaces (Schematic page 1)
Page 1 of the schematics shows the microcontroller, CAN port, RS232 port, and sensor interfaces
in detail.
January 4, 2012
15
Hardware Description
Microcontroller
At the core of the MDL-BDC24 is a Stellaris LM3S2616 microcontroller. The LM3S2616 contains a
peripheral set that is optimized for networked control of motors, including 6 high-speed ADC
channels, a motor control PWM block, a quadrature encoder input, as well as a CAN module.
The microcontroller's PWM module can generate two complementary PWM signal pairs that are
fed to the power stage. Complementary PWMs are important for synchronous rectification (see
“Output Stage and Power Supplies (Schematic page 2)” on page 17).
The LM3S2616 has an internal LDO voltage regulator that supplies 2.5 V power for internal use.
This rail requires only three capacitors for decoupling and is not connected to any other circuits.
Clocking for the LM3S2616 is facilitated by a 16 MHz crystal. Although the LM3S2616 can operate
at up to 50 MHz, in order to minimize power consumption, the PLL is not enabled in this design.
The 32-bit Cortex-M3 core has ample processing power to support all features including 1 Mbits/s
CAN and RS232 with a clock speed of 16 MHz.
Debugging
The microcontroller supports JTAG and SWD debugging as well as SWO trace capabilities. To
minimize the board area, the MDL-BDC24 uses a 0.050" pitch header footprint which matches
ARM's fine-pitch definition (Figure 4-2). The connections are located on the bottom of the module,
under the serial number label. The module included in the reference design kit has a header
installed; however, the standard MDL-BDC24 (available as a separate item) does not have the
header installed.
Some in-circuit debuggers provide a matching connector. Other ARM debuggers can be used with
the adapter board included in the RDK.
Figure 4-2.
MDL-BDC24 JTAG/SWD Connector
1 2
TMS/SWDIO
TCK/SWCLK
TDO
TDI
SRSTn
+3.3V
GND
GND
GND
9 10
Figure 4-2 shows the pin assignments for the JTAG/SWD connector as viewed from the bottom
(connector) side of the circuit board.
CAN Communication
A key feature of the LM3S2616 microcontroller is its CAN module that enables highly reliable
communications at up to 1 Mbits/s. The MDL-BDC24 control board uses a Texas Instruments
SN65HVD1050D CAN transceiver (U2), additional ESD protection (D6), and connectors. The pin
assignments for the 6P6C/6P4C connectors are defined in CAN in Automation (CiA DS102).
Figure 4-3 shows the network connector pin assignments.
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January 4, 2012
Stellaris® Brushed DC Motor Control User’s Manual
Figure 4-3.
Network Connector Pin Assignments
CANH CANL
V+
CANH CANL
GND
RXD
V+
GND
TXD
1
6
6P6C RS232/CAN Socket Viewed
from Top (Tab down)
1
6
6P4C CAN Socket Viewed
from Top (Tab down)
The V+ signal (Pin 2) is not used in the MDL-BDC24, however, it is passed through to support
other devices that either provide or use power from this terminal. The typical application for V+ is
in providing a small amount of power to optocouplers for isolating CAN signals.
For 1-Mbps CAN communication over distances up to 20 feet, the network should be terminated at
each end with a 100Ω resistor. This value is slightly lower the normal 120Ω terminator, but it
accelerates the bus’ return to the recessive state which is important in high-data rate, high
node-count applications.
RS232 Communication
The MDL-BDC24 supports a full set of network control and configuration functions over a standard
RS232C serial interface. The command protocol is essentially the same as the protocol used on
the CAN interface, thereby allowing the MDL-BDC24 to automatically bridge all commands
between the RS232 and CAN interfaces.
A TRS3221E RS232 transceiver was selected to translate the CMOS logic levels from the
LM3S2616's UART0 to RS232 levels. Its internal charge-pump generates positive and negative
voltages from the +5 V supply pin. Integrated ESD protection means that no external protection
device is necessary.
Other Interfaces
Interfaces for an encoder (or tachometer), limit switches, and brake control are provided on 0.1"
pin headers. The connections to the microcontroller are ESD-protected and in most cases have
10 kΩ pull-up resistors.
The brake and user switch inputs use the LM3S2616 microcontroller's internal pull-up resistor.
The analog input has a 0 to 3 V span. In order to use a 10 kΩ potentiometer, a 1 kΩ “padding”
resistor is provided on J4.1 to drop 300 mV from the 3.3 V rail when the potentiometer is
connected.
Output Stage and Power Supplies (Schematic page 2)
Page 2 of the schematics details the power supplies, gate drivers, output transistors, sensing, and
fan control circuits.
January 4, 2012
17
Hardware Description
Motor Output Stage
The motor output stage consists of an H-bridge with High-/Low-side gate drivers. Each leg of the
H-bridge has two paralleled MOSFETs. The MOSFETs are connected in parallel to reduce total
Rds (on) to about 2.5 mΩ and to provide additional surface area for fan cooling. The fan blows
directly on the TO-220 MOSFETs, which are arranged radially around the DC bus capacitor. A
plastic ring encompasses the MOSFETs providing mechanical support and ensuring that the tabs
do not touch.
The gate driver provides high peak currents to rapidly switch the gates of the MOSFETs when
directed by the microcontroller’s PWM module. An internal charge-pump allows the drivers to
maintain MOSFET gate voltage, even under low-voltage conditions. Resistor R34 sets the gate
drive dead-time to approximately 2μs.
Because the high-side MOSFETs are N-Channel types, a positive Vgs is required to switch them
on. The gate driver uses a simple boot-strapping technique to ensure that the high-side Vgs
remains above the Vgs (on) threshold. Whenever the low-side MOSFETs are on, the associated
boot-strap capacitor (C34 or C36) charges from the internal charge-pump regulator. Later, when
the high-side MOSFETs turn on, the boot-strap capacitor maintains power to the high-side driver
with respect to the Motor terminal.
One restriction with the boot-strap capacitor method is that the capacitor voltage will decay to an
unacceptable level unless a low-side MOSFET is periodically switched on. This state only occurs
when the motor is running full-forward or full-reverse. The gate driver has an internal sense circuit
the inserts small low-side pulses whenever the bootstrap voltage decays. The short duration has
no measurable impact on motor speed. The boot-strap monitor capability is the reason that the
gate driver controls dead-time rather than the LM3S2616 microcontroller.
Switching Scheme
To reduce power dissipation in the H-bridge, the MDL-BDC24 uses synchronous rectification.
Synchronous rectification uses the complementary MOSFET, rather than a diode, to provide a
low-resistance current path during the PWM off period.
Figure 4-4 shows the current paths through a complete PWM_ON, Dead-time, PWM_OFF cycle.
The motor is modelled primarily as an inductor.
During the PWM_ON period, Q1 on the high-side and Q2 on the low-side provide a path that
increases current in the motor.
The 2μs DEAD_TIME period starts with Q1 turning OFF. Current continues to flow through the
load, with the path being completed by the Q2 intrinsic diode and Q4. The voltage drop across Q2
is equal to a forward-biased diode.
Next, the synchronous rectification period, PWM_OFF, occurs when Q2 is ON. The voltage drop
across Q2 is now greatly reduced. The load current decays during this period.
18
January 4, 2012
Stellaris® Brushed DC Motor Control User’s Manual
Figure 4-4.
Synchronous Rectification
+VM
PWM_ON
Q1g
Q1
Q3
Q3g
Motor
PWM_OFF
Q2g
DEAD_TIME
Q2
Q4
Q4g
During PWM_OFF, assuming a 40 A load, Q2 losses are approximately 40W without synchronous
rectification. This drops to just 4W if synchronous rectification is used (Rds-on = 2.5 mΩ).
Synchronous rectification significantly improves drive-stage efficiency, particularly at lower duty
cycles (50% and less) when the PWM_OFF time is longer that the PWM_ON time.
Power Supply
The MDL-BDC24 uses a TPS54040-based switching power supply for optimal efficiency over a
wide operating range. Resistor R20 sets the switching frequency at around 700kHz, which allows
the use of a small inductor and output capacitor.
The 5-V rail is used for the cooling fan, CAN and RS232 transceivers, current sense amplifier, and
quadrature encoder functions. A low drop-out voltage linear regulator (TPS73633) generates the
3.3-V rail which is used by the MCU and peripheral circuitry.
Current Sensing
The current sensing circuit consists of a high-side shunt resistor (R23) and a specialized current
sense amplifier (INA193). Due to the high current capabilities of the bridge, the shunt resistor is
just 1 mΩ. The INA193 amplifier has a fixed gain of 20 V/V which results in a signal into the ADC of
20 mV/A for a full-scale reading of 150 A. Because the sense resistor is in the high-side of the
H-bridge, the current through it is only positive when the high-side MOSFETs are on. The
MDL-BDC24 software takes this into consideration when sampling the current waveform.
When operating smaller motors, or lightly-loaded large motors, the INA193 may be operating with
a Vsense less than 20 mV. This region has reduced current sense amplifier accuracy. See the
INA193 data sheet for full details on Low Vsense Case 1 and Case 3.
The PCB design has an option to populate an INA282 current sense amplifier. This was done to
evaluate a future build option. The INA282 and supporting components are omitted from the
assembly.
January 4, 2012
19
Hardware Description
Voltage Sensing
A simple divider resistor network (16 and R18) scales the Vbus rail down to the range of the ADC
(0-3 V). The full-scale ADC measurement (ADC=1023) corresponds to a bus voltage of 36 V.
Fan Control
The cooling fan is self-contained and uses a small, 5 V brushless DC motor. The MDL-BDC24
supports On/Off software control of the fan using Q3. The fan operates when the motor is running
or when the temperature exceeds a certain threshold. The LM3S2616 microcontroller has an
internal temperature sensor and a simple software table correlates the microcontroller temperature
to the overall system temperature.
Texas Instruments’ Featured Parts
The MDL-BDC24 features a range of semiconductors from Texas Instruments as shown in
Table 4-1.
Table 4-1. Detailed List of Texas Instruments’ Featured Parts
Part Number
Description
Use
Features
LM3S2616
Stellaris®
Microcontroller
System control
SN65HVD1050
High-Speed EMC
Optimized CAN
Transceiver
CAN
communications
TRS3221E
Single-Channel
RS-232
Compatible Line
Driver/Receiver
RS232
communications
•
•
•
•
•
•
•
•
•
•
•
•
TPS54040
0.5 A Step Down
SWIFT™
Converter with
Eco-Mode™
5V Power Supply
TPS73633
INA193
20
Cap-Free, NMOS,
400 mA
LowHDropout
Regulator with
Reverse Current
Protection
3.3V Power
Supply
Voltage Output
High-Side
Measurement
Current Shunt
Monitor
Motor current
measurement
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
ARM® Cortex™-M3 core
Motion control capabilities
64 KB Flash.
High electromagnetic immunity (EMI)
Very low electromagnetic emissions (EME)
Bus-fault protection of -27 V to 40 V
Dominant time-out function
Power-up/down glitch-free bus inputs and outputs
Operates up to 250 kbits/sec
Low standby current... 1 µA Typ
External Capacitors... 4 × 0.1 µF
RS-232 bus-pin ESD protection exceeds ±15 kV using
human-body model (HBM)
3.5 V to 42 V input voltage range
200-mΩ high-side MOSFET
High efficiency at light loads with a pulse skipping
Eco-Mode™
100 kHz to 2.5 MHz switching frequency
Stable with no output capacitor or any value or type of
capacitor
Input voltage range of 1.7 V to 5.5 V
Ultra-low dropout voltage: 75 mV typ
Excellent load transient response
Low reverse leakage current
Low noise: 30 ìVRMS typ (10 Hz to 100 kHz)
0.5% initial accuracy
Wide common-mode voltage –16 V to +80 V
Low error 3.0% over temp (max)
Wide bandwidth: up to 500 kHz
Low quiescent current 900 vvµA (max)
Complete current sense solution
January 4, 2012
A P P E N D I X A
Schematics
This section contains the schematic diagrams for the RDK-BDC24.
„
MCU, Network, and Interface on page 22
„
Power Supplies and Output Stage on page 23
January 4, 2012
21
Schematic page 1
1
2
3
4
5
Status LED
Calibrate/ID
LED_GRN R1
100
SW1
U1
LED_RED
R4
U0RX
U0TX
LED_GRN
SPDIN
CANRX
CANTX
K
A2
Red
150
A
U3
Green
A1
SWITCH
SW-B3S1000
6
D1
AHI
ALO
+3.3V
17
18
19
20
21
22
25
26
+3.3V
PA0/U0RX
PA1/U0TX
PA2/PWM4
PA3/PWM5
PA4/CAN0Rx
PA5/CAN0Tx
PA6/PWM0
PA7/PWM1
PB0/PWM2
PB1/PWM3
PB2/I2C0SCL
PB3/I2C0SDA
PB4/C0PB5/C1PB6/C0+
PB7/NMI
41
42
47
27
58
57
56
55
BHI
BLO
C1
R3
1.0K
+5V
6
1
5
2
4
3
0.1UF
SPDIN
GD_RESETn
FAN_ON
FAN_ON
LIMIT2
LIMIT1
J1
R2
1
2
3
150
FEMALE-1X3
PWM Speed Input
+3.3V
J2
1
3
5
7
9
TCK/SWCLK
TMS/SWDIO
TDI
TDO
QE_A
R5
10K
TMS/SWDIO
TCK/SWCLK
TDO
TDI
RESETn
2
4
6
8
10
GD_FAULTn
QE_B
LED_RED
CON-HDR-2X5-050
OMIT
OSC0
OSC1
34
35
PD0/IDX0
PD1
PD2/ADC5
PD3/ADC4
PE0/ADC3
PE1/ADC2
PE2/ADC1
PE3/ADC0
PE4/FAULT0
+3.3V
61
62
63
64
6
5
2
1
8
QE_INDEX
BOARD_ID
BRAKE_EN
D2
ISENSE_193
POT/ANA
VSENSE
SWITCH
NC
NC
NC
TP2
SPDIN
TP3
TMS/SWDIO
TP4
TCK/SWCLK
TP5
TDO
TP6
TDI
TP7
FANN
C2
C3
10PF
10PF
32
33
R7
10K
RESETn
C8
0.01UF
FANN
TP8
+3.3V
C40
2
GSOT05C
R6
0.1UF
1.0K J3
1
+
2
S
3
-
VSENSE
45
46
48
HDR-1X3
10K Position Pot
WAKE
HIB
40
RST
10
13
24
29
36
39
44
53
60
4
RS232 Transceiver
VDDA
VDD33
VDD33
VDD33
VDD33
GND
GND
GND
GND
GND
GND
GND
GND
GND
GNDA
VBAT
LDO
VDD25
VDD25
VDD25
VDD25
3
12
28
43
59
C4
C5
C6
0.01UF 0.01UF 0.1UF
C7
0.1UF
16
12
1
3
7
C14
C15
0.1UF 0.1UF 14
ROUT
FORCEOFF
FORCEON
EN
2
V+
VGND
TXD
8
RXD
6
5
4
3
2
1
5 C13
6
C2+
C2-
CAN Transceiver
0.1UF
U2
0.1UF
CANTX
CANRX
1
4
+5V
15
VCC
8
C16
2
TRSF3221E
0.1UF
TXD
RXD
6
5
4
3
2
1
VCC
VREF
SN65HVD1050D
R11
10K
C17
0.1UF
D6
GSOT05C
J5
1
2
Jumper Installed (default)
HDR-1X2
Limit Switch #2 (Reverse)
1
+3.3V
2
R12
10K
J7
GSOT05C
LIMIT1
1
2
Jumper Installed (default)
HDR-1X2
Limit Switch #1 (Forward)
CAN Port
RJ11-6P-VERT
Date
0
Sept 9, 09
Internal Prototype
TI AEC - Austin
A
Sept 11, 09
Pre-production. See Round-up for change list.
A1
Sept 14, 09
Change to use conventional Isense resistors.
108 Wild Basin Rd.
Suite 350
Austin, TX 78746
C
D
Sept 21, 09
Pre-production release.
Designer:
Oct 7, 09
Adjust Isense and SMPS circuit values.
DAY, JAG, KAK
Sept 9, 10
Added INA282 current sense circuit as a
future build option. INA282 parts are omitted.
Drawn by:
Removed INA282 current sense option.
Added Additional 10uF to 5V and 3.3V rail
Approved:
Sept 21, 11
Drawing Title:
Page Title:
DAY, JAG, KAK
MCU, Network and Interface
Size
3
4
Document Number:
B
*
2
D
Black Jaguar Brushed DC Motor Control
Date:
1
C
D5
CAN/RS232 Port
Revision
B
Description
3
5
PIN 6
PIN 5
PIN 4
PIN 3
PIN 2
PIN 1
GSOT05C
LIMIT2
J8
7
6
+5V
RS
GND
PIN 6
PIN 5
PIN 4
PIN 3
PIN 2
PIN 1
RJ11-6P-VERT
CANH
CANL
+
A
B
I
-
HDR-1X5
Encoder
C11
1UF
+3.3V
13
2 C12
4
C1+
C1-
1
2
3
4
5
1
10
INVALID
J4
D4
C9
C10
0.01UF 0.1UF
J6
RIN
2
7
9
23
38
54
2
+5V
0.1UF
R10
10K
QE_A
QE_B
QE_INDEX
LM3S2616
DOUT
R9
10K
GSOT05C
37
1
9
U0RX
DIN
C39
1
R8
10K
3
11
U0TX
B
+5V
D3
+5V
U4
D
Brake (default)
+3.3V
+3.3V
C
Coast
HDR-1X3
Brake/Coast Jumper
1
R24
1.0K
OMIT
JP1
1
2
3
POT/ANA
XOSC0
XOSC1
+3.3V
16.00MHz
Factory Test
TP1
PC0/TCK/SWCLK
PC1/TMS/SWDIO
PC2/TDI
PC3/TDO/SWO
PC4/PhA0
PC5/C0o
PC6/PhB0
PC7/C1+/C1o
30
31
Y1
B
52
51
50
49
11
14
15
16
A
H11L1M
BRAKE_EN
Debug
S
+
-
5
Rev
*
9/21/2011
D
Sheet
1
6
of
2
Schematic page 2
1
2
3
4
5
6
C18
1
2
BOOT
VIN
PH
COMP
10
8
1
T2
4
5
R17
82K
C29
(Blk)
0.01UF
R20
162K
EN
SS/TR
RT/CLK
GND
35V
C23
1.0UF
50V
PwPd
3
C22
1.0UF
50V
VSNS
PwRGD
C25
C26
0.01UF
7
6
R15
10K
D7
SS16
10PF
R19
1.87K
9
V-
C21
1800uF
R14
82K
11
+
IN
+3.3V
5
OUT
47uH
R13
390K
(Red)
U6
TPS73633DBV
+5V
3
C24
10UF
16v
EN
C19
1UF
C38
10UF
16v
GND
+VBAT
T1
A
L1
SLF7045T-470MR90-H
0.1UF
U5
TPS54040
4
NR
A
C20
1UF
2
12-24V POWER IN
V+
C30
10UF
16v
C27
0.01UF
PWRGD
TP9
+5V
+5V_SHUNT
FB1
1K ohm @ 100 MHz
C35
0.1UF
5
+VBAT
+
GND V+
3
R23
0.001
4
-
2
B
1
OUT
ISENSE_193
U7
INA193AID
B
+VM
Q2
2
1
3
R21
27
1
R22
27
3
Q1
2
+VM
+VM
C41
0.1UF
OMIT
Motor +
MOTOR+
ALO
+3.3V
BHI
R28
10K
BLO
18
17
24
1
GD_FAULTn
CB
GHB
SB
GLB
BHI
BLO
FAULT
RESET
CP1
CP2
RDEAD
AGND
GND
GND
GND
2
2
1
3
R27
27
C42
0.1UF
OMIT
C
Cooling Fan Control
1
2
FANN
C36
1UF
+VM
1
FAN_ON
Q6
14
13
2
15
16
C37
1UF
Q7
1
R29
27
1
R30
27
MOLEX 35362
5V Fan
Q3
FDV301N
Motor T4
Z2
Q9
2
1
3
R32
27
1
R33
27
3
Q8
2
A4940
(Green)
Drawing Title:
VC080530A650DP
Page Title:
Power Supplies and Output Stage
Document Number:
B
Date:
3
D
Black Jaguar Brushed DC Motor Control
C44
0.1UF
OMIT
Size
2
Red
Black
C43
0.1UF
OMIT
MOTOR-
D
1
J9
+5V
25
23
22
R34
82.0K
PAD
GD_RESETn
6
5
4
3
R26
27
3
CA
GHA
SA
GLA
AHI
8
9
10
11
C34
1UF
2
19
12
C28
0.01UF
2
ALO
20
VBB
(White)
R18
1.0K
VC080530A650DP
3
AHI
VDD
VREG
3
21
7
Q5
1
3
10UF
16v
Q4
U8
0.1UF
C33
C
+VBAT
C32
0.1UF
2
+3.3V
VSENSE
T3
Z1
C31
R16
11.0K
4
5
Rev
D
*
10/14/2011
Sheet
2
6
of
2
A P P E N D I X B
Board Drawing
This appendix shows the component placement plot for top (Figure B-1)
Figure B-1. Component Placement Plot
January 4, 2012
24
A P P E N D I X C
Bill of Materials (BOM)
Table C-1 provides the BOM for the RDK-BDC24.
Table C-1. RDK-BDC24 Bill of Materials (BOM)
Texas Instruments
Part Number
BD-BDC24 Final Assembly BOM (PCB Assembly + Enclosure)
Bill Of Materials
Created
Item Ref
1
C1, C6, C7, C10,
C12, C13, C14,
C15, C16, C17,
C18, C31, C32,
C39, C40
2
C11, C19, C20,
C34, C36, C37
9/21/2011
Description
Mfg
Part Number
15
Capacitor, 0.1uF 50V, 20% 0805 X7R
Kemet
C0805C104M5RACTU
6
Capacitor, 1.0uF 25V 10% X5R 0805
Taiyo Yuden
TMK212BJ105KG-T
3
C2, C3, C25
3
Capacitor 10pF 50V 5% 0805 COG
Kemet
C0805C100J5GACTU
4
C21
1
Panasonic
EEU-FC1V182S
5
C22, C23
2
Capacitor, 1800uF 35V 20%
18mmx20mm
Capacitor, 2.2uF 50V 10% X7R 1210
Kemet
C1210C225K5RACTU
6
C24, C30, C33,
C38
C35
4
Capacitor, 10uF 16V 10% X7R 1210
Murata
GRM32DR71C106KA01L
1
Capacitor, 0.1uF 50V, 20% 0603 X7R
TDK
C1608X7R1H104M
Kemet
C0603C104M5RACTU
7
8
9
C4, C5, C8, C9,
C26, C27, C28,
C29
D1
8
Capacitor, 0.01uF 50V, 5% 0805 X7R
Kemet
C0805C103J5RACTU
1
LED, Green, Red, 5mm T-hole, dual
Kingbright Corp
WP59SRSGW/CC
10
D1b
1
SPACER, PCB-LED T1-3/4, 109Mil
Keystone
8902
11
D2, D3, D4, D5,
D6
5
Diode, 2 Line 5V ESD Suppressor SOT23
Vishay
GSOT05C-GS08
D7
1
Diode, Schottky, 60V, 1A
ON
Semiconductor
Vishay
SM05T1G
12
13
FB1
1
Ferrite Bead, 400mA, 1K Ohm@100Mhz Murata
BLM18AG102SN1D
14
J1
1
Header, 1x3, 0.100, T-Hole, Vertical,
Female
4UCON
00523
Sullins
PPTC031LFBN-RC
15
J3, JP1
2
Header, 1x3, 0.100, T-Hole, Vertical
Unshrouded, 0.230 Mate
4UCON
00798
FCI
68001-103HLF
4UCON
00806
FCI
68000-105HLF
FCI
67997-104HLF
4UCON
00998
FCI
90512-001LF
16
January 4, 2012
Qty
RDK-BDC24 Rev D
J4
1
Header, 1x5, 0.100, T-Hole, Vertical
Unshrouded, 0.230 Mate
SS16-E3/61T
17
J5, J7
(Combined)
1
Header, 2x2, 0.100, T-Hole, Vertical
Unshrouded, 0.230 Mate
18
J6
1
Connector, RJ11 Mod-Jack 6-6 Vert
Flange Blk
4UCON
04912
19
J8
1
Connector, RJ11 Mod-Jack 6-4 Vert
Flange Blk
FCI
90512-003LF
4UCON
04911
20
J9
1
Molex
35362-0250
TDK
SLF7045T-470MR90-H
21
L1
1
22
PCB 1
1
Header, 1x2 Surelock 2mm, Thole
Vertical, shrouded
Inductor 47uH, SMD 7mmx7mm, 0.9A,
0.18Ohm
PCB, RDK, DD, BlackJag Rev D
23
Q1, Q2, Q4, Q5,
Q6, Q7, Q8, Q9
8
MOSFET N-CH, TO-220 40V/60V 80A
Anyone
RDK-BLKJAG-D
International
Rectifier
IRFB3206PBF
Fairchild
FDP038AN06A0
Fairchild
FDP050AN06A0
25
Table C-1. RDK-BDC24 Bill of Materials (BOM) (continued)
Texas Instruments
Part Number
BD-BDC24 Final Assembly BOM (PCB Assembly + Enclosure)
Bill Of Materials
Created
9/21/2011
Item Ref
Qty
RDK-BDC24 Rev D
Description
Mfg
Part Number
Fairchild
FDV301N
24
Q3
1
MOSFET, N-CH, SOT-23, 25V, 220mA
25
R1
1
Resistor, 100 OHM 1/8W 5% 0805 Thick Panasonic
ERJ-6GEYJ101V
26
R13
1
CRCW0805390KFKEA
27
R14, R17
2
Resistor, 390K Ohm, 1/8W, 1% 0805
Vishay
Thick
Resistor, 82K OHM 1/8W 5% 0805 Thick Panasonic
28
R16
1
ERJ-6ENF1102V
29
R19
1
30
R2, R4
2
Resistor, 11K Ohm, 1/8W, 1% 0805
Panasonic
Thick
Resistor, 1.87K Ohm, 1/8W, 1% 0805
Yageo
Thick
Resistor, 150 OHM 1/8W 5% 0805 Thick Panasonic
31
R20
1
32
8
33
R21, R22, R26,
R27, R29, R30,
R32, R33
R23
34
R3, R6, R18
3
35
R34
1
36
9
37
R5, R7, R8, R9,
R10, R11, R12,
R15, R28
SW1
1
Switch, Tact 6mm SMT, 160gf
38
T1
1
39
T2
1
40
T3
1
41
T4
1
42
U1
1
Terminal, Screw Vertical 15A Red Screw
non captive
Terminal, Screw Vertical 15A Black
Screw - non captive
Terminal, Screw Vertical 15A White
Screw - non captive
Terminal, Screw Vertical 15A Green
Screw - non captive
IC, Optocoupler Schmitt Trigger SMD-6
43
U2
1
CAN Transceiver 8-SOIC
44
U3
1
45
U4
1
1
46
U5
1
47
U6
1
48
U7
1
49
U8
1
50
Y1
1
51
Z1, Z2
2
Resistor, 162K Ohm, 1/8W, 1% 0805
Thick
Resistor, 27 OHM 1/8W 5% 0805 Thick
ERJ-6GEYJ823V
RC0805FR-071K87L
ERJ-6GEYJ151V
Rohm
MCR10EZPF1623
Panasonic
ERJ-6GEYJ270V
Resistor, 0.001 OHM, 4W 1% 2725 SMD Stackpole
Electronics
Resistor, 1K Ohm, 1/8W, 1% 0805
Panasonic
Thick
Resistor, 47K OHM 1/8W 5% 0805 Thick Rohm
CSS2725FT1L00
Resistor, 10K Ohm, 1/8W, 1% 0805
Thick
ERJ-6ENF1002V
Panasonic
Omron
MCR10EZPJ473
B3S-1000
- Keystone
8191-2
Keystone
8191-3
Keystone
8191-4
Keystone
8191-6
Fairchild
H11L1SR2M
Fairchild
H11L1SR2VM
Texas
Instruments
Stellaris, LM3S2616-IQR50-A0
Texas
Instruments
RS232, Line Driver, 3V to 5.5V, Single
Texas
Channel, TSSOP 16
Instruments
Texas
Instruments
Texas
Regulator, SWIFT, Step Down, 0.5A,
Instruments
42V, MSOP10
Regulator, Linear, 3.3V, SOT23-5 (DBV) Texas
Instruments
Texas
Current Shunt Monitor, INA193, 20V/V
Instruments
Gain, 5SOT-23
Full Bridge MOSFET Driver, Allegro, 24- Allegro
eTSSOP
Crystal, 16.00MHz 5.0x3.2mm SMT
NDK
TVS Varistor, 30V, 30A, Transguard
ERJ-6ENF1001V
SN65HVD1050D
LM3S2616-IQR50-A0
TRS3221ECPWR
MAX3221ECPW
TPS54040DGQ
TPS73633DBV
INA193AIDBVR
A4940KLPTR-T
Abracon
NX5032GA16.000000MHZ
ABM3-16.000MHZ-B2-T
AVX
VC080530A650DP
Final Assembly Bill Of Materials
26
January 4, 2012
Stellaris® Brushed DC Motor Control User’s Manual
Table C-1. RDK-BDC24 Bill of Materials (BOM) (continued)
Texas Instruments
Part Number
BD-BDC24 Final Assembly BOM (PCB Assembly + Enclosure)
Bill Of Materials
Created
9/21/2011
Item Ref
Part Number
52
Description
Mfg
3
Jumper, 0.100, Gold, Black, Closed
Sullins
SPC02SYAN
53
1
Fan Assembly, 40x40x10mm, 5V,
5.3CFM, 2" Lead w/ Molex Sherlock
connector
SUNON
KDE0504PFV2
ebmpapst
405 FH
54
1
Enclosure, ABS plastic 3 pieces
Cypress
LM-608-01
55
1
Label, with Model/Serial/Firmware info
Anyone
BJAG-LABELS
56
4
McMaster
90380A108
57
4
Screw, #4 x 0.375" plastite (for
enclosure )
Screw, #4 x 0.625" Pan Head, Sheet
Metal, Phillips/Slotted (for fan )
McMaster
90077A112
58
1
January 4, 2012
JP1b, J5b, J7b
Qty
RDK-BDC24 Rev D
BOM, PCB, Black Jaguar, Rev D
27
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