How to Optimize Motor Drive Systems in Industrial AutomationKey Aspects of Rapid Prototyping for Servo Drives

Ing Mattia Rossimattiarossipolimiit

Politecnico di MilanoElectrical Machines Drives and Power Electronics Research GroupDepartment of Mechanical Engineering (DMECC)

2Politecnico di Milano

Lombardia

bull Cittagrave Studi (Leonardo)bull Bovisa

Milan Campus

o Engineering since 1863o Architecture since 1865o Industrial design since 2000

Number of students gt 45 000 (2019)engineering 32 328

Leonardo Bovisa

(Northern Italy)

httpwwwpolimiit

3Politecnico di Milano

Electrical Machines Drives and Power Electronics Research Group

Meccanica dei Sistemi

Prof Francesco Castelli-Dezzafrancescocastellidezzapolimiit

Head person

Location Department of Mechanical Engineering (DMECC)Campus Bovisa La MasaVia La Masa 1 20256 Milan ItalyBuilding B23httpswwwmeccpolimiit

Mattia RossiNicola ToscaniMatteo SpositoAndrea PolastriMarco MauriStefania CarmeliLuca GrittiniAlessandro GrittiniMassimo Brunetti

4Politecnico di Milano

Location Department of Mechanical Engineering (DMECC)Campus Bovisa La MasaVia La Masa 1 20256 Milan ItalyBuilding B23httpswwwmeccpolimiit

Electrical Machines Drives and Power Electronics Research Group

Design and advanced control of LVMV systems Control of electrical drives Smart actuatorssensors Analysis of system efficiency (power losses)

and reliability of power electronic-based systems

Industrial fields energy conversion railways e-mobility

Research Areas

5

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

6Past Present and Future Motion Control Systems

The path on the development of motion control systemshellip

Source ETH Research Vectors in Power Electronics and Motion Control

James Wattrsquos Steam Engine Nikola Teslarsquos amp Galileo FerrarisAC induction machine

Integrated drive system (AC motor + SkiNIGBTpower electronics) for todayrsquos electric vehicles

Exponential development

lt 1900 Mechanical

1900 Mechanical + Electrical

1950 Mechanical + Electrical + Electronic Electronic Motion Control

1975 Mechanical + Electrical + Electronic + Computation

1985 Mechanical + Electrical + Electronic + Computation + InformationCommunication

2000 Mechanical + Electrical + Electronic + (Large) Computation + IoT

7Past Present and Future Motion Control Systems

Future innovation in the development of motion control systems

Key components are today available with high performance

1st Option for gaining a competitive advantage further optimize the laquocomponentsraquo

eg Ultra-High Speed Machines Ultra-Efficient Converter

2nd Option for gaining a competitive advantage target specific mechatronic system needs

eg System level optimization and Integration (eg many servo drives)

Extremely Wide Application Areas

bull Machining

bull Handling and Assembly

bull Transportation (land sea air)

bull Gas Oil and Mining

bull Water Wastewater

bull Consumer Electronics

bull Computers

bull Home Appliances

bull Defense

bull Medical

bull Space Exploration

Compact amp EfficientPower Converter

High-Performance Mechanical Actuators

High-Performance MCU and SoC-based Platforms

Precision Sensors Wide Communication

Compact amp EfficientElectrical Machines

Component level

System level

8Past Present and Future Motion Control Systems

2nd Option for gaining a competitive advantage target specific mechatronic system needs

This is practically achieved by targeting the laquoSystem Levelraquoand have competences to bridge the boundaries between more (gt) than 3 key areas

This already represent the TODAY scenariohellip

Opens Path to Endless Product Innovation

Industrial automation

Source ETH Research Vectors in Power Electronics and Motion Control

9Industrial Automation

The industrial robot system case study

Low-level controlHigh-level control

All sub-systems must be optimized

decentralized

architecture

10

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

11Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

Machines ranging from devices like drills and logistics to complex equipment like industrial robots make a wide use of

brushed and brushless DC motors (BLDC) and permanent magnet synchronous motor (PMSM)

BLDC motors and PMSMs are similarly structured both have permanent magnets (PM) in the rotor and are defined as synchronous motors

There are motors with different PM arrangements where the stator may have different numbers of windings and the rotor multiple pole pairs

However the way BLDC motors and PMSMs are controlled is very differentdue to the difference in the shape of their back EMF (electromotive force)

Rotor single pole pairStator three coils spaced at 120deg

12Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

When electrical motors are rotated a voltage is induced in the stator that opposes the driving voltage of the motor

Back EMF is an important characteristic as its shape dictates the kind of algorithm required to optimally control it

Due to their design BLDC motors have a trapezoidal back EMF and are controlled by trapezoidal commutation

BLDC

Trapezoidal Back EMF

Controlled by trapezoidal commutation

PMSM

Sinusoidal Back EMF

Controlled by field-oriented control

Six-Step Commutation (or Trapezoidal Control)

bull The coils which are here referred to as phases A B and C can be energized by passing a current through them

bull Applying voltage across two phases A and C (in the animation) generates a combined magnetic field along the dashed line The rotor turns to align itself with the stator magnetic field

13

BLDC Six-Step Commutation

bull There are six possible ways of energizing coil pairsBy commutating two phases at a time the resulting stator magnetic field is rotated

bull The rotor angle is measured with respect to the horizontal axis and there are six different rotor alignmentseach 60 degrees apart from each otherThis means that if the correct phases are commutated every 60 degrees the motor will continuously spin

Electrical MachinesDrives

From here the name six-step commutation (or trapezoidal control)

More pole pairs can be added to such machines requiring for the commutation to take place more often

bull 1 pole pair 60deg 2 pole pairs 30deg 4 pole-pairs 15deg

To properly commutate the motor at the right times with the correct phases the controller needs to know the exact position of the rotor at any time which is usually measured by using

Hall sensors

14

bull By adjusting the applied voltage is varied the motor speed

Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

To control the phases during six-step commutation a three-phase inverter is used to direct the DC power to the

three phases switching between positive (red) and negative (blue) current

To supply positive current to one of the phases the high side switch connected to that phase needs to be turned on

bull Doing this while the rotor is at an angle between 60 and 120degto the stator magnetic field the three-phase inverter keeps the motor rotating at a constant speed

15Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

From the control point of view the system has a dynamic behavior very similar to a (brushed) PM DC motor

(That is why is called BLDC)

used to compute the sector

T1T4 T1T6 T3T6 T3T2 T5T2 T5T4

Look-up table

speed calc

hall

BLDC

com

mu

tati

on

tab

le

16Electrical MachinesDrives

BLDC Six-Step Commutation vs PMSM

There are two reasons for switching phases in BLDC motors in Six-Step Commutation

If the rotor and stator magnetic fields were allowed to align perfectly the motor would create zero torque

Maximum torque occurs when the fields are at 90 degto each otherThe goal therefore is to bring this angle close to 90deg

Pros

simple nature of trapezoidal control

Cons

torquecurrent is quite noise due to the nature of the switching

sequence (ie two phases) losses and harmonic excitation

More advanced techniques such as field-oriented

control (FOC) commonly used to control PMSMs

allows generation of larger torques (by achieving 90deg

between the stator and rotor magnetic fields) and

lower harmonic content

17

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

18Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

Control Logic Power Stage

TI C2000 MCUs LaunchPad

TI BoosterPacks PMSM

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

6Past Present and Future Motion Control Systems

The path on the development of motion control systemshellip

Source ETH Research Vectors in Power Electronics and Motion Control

James Wattrsquos Steam Engine Nikola Teslarsquos amp Galileo FerrarisAC induction machine

Integrated drive system (AC motor + SkiNIGBTpower electronics) for todayrsquos electric vehicles

Exponential development

lt 1900 Mechanical

1900 Mechanical + Electrical

1950 Mechanical + Electrical + Electronic Electronic Motion Control

1975 Mechanical + Electrical + Electronic + Computation

1985 Mechanical + Electrical + Electronic + Computation + InformationCommunication

2000 Mechanical + Electrical + Electronic + (Large) Computation + IoT

7Past Present and Future Motion Control Systems

Future innovation in the development of motion control systems

Key components are today available with high performance

1st Option for gaining a competitive advantage further optimize the laquocomponentsraquo

eg Ultra-High Speed Machines Ultra-Efficient Converter

2nd Option for gaining a competitive advantage target specific mechatronic system needs

eg System level optimization and Integration (eg many servo drives)

Extremely Wide Application Areas

bull Machining

bull Handling and Assembly

bull Transportation (land sea air)

bull Gas Oil and Mining

bull Water Wastewater

bull Consumer Electronics

bull Computers

bull Home Appliances

bull Defense

bull Medical

bull Space Exploration

Compact amp EfficientPower Converter

High-Performance Mechanical Actuators

High-Performance MCU and SoC-based Platforms

Precision Sensors Wide Communication

Compact amp EfficientElectrical Machines

Component level

System level

8Past Present and Future Motion Control Systems

2nd Option for gaining a competitive advantage target specific mechatronic system needs

This is practically achieved by targeting the laquoSystem Levelraquoand have competences to bridge the boundaries between more (gt) than 3 key areas

This already represent the TODAY scenariohellip

Opens Path to Endless Product Innovation

Industrial automation

Source ETH Research Vectors in Power Electronics and Motion Control

9Industrial Automation

The industrial robot system case study

Low-level controlHigh-level control

All sub-systems must be optimized

decentralized

architecture

10

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

11Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

Machines ranging from devices like drills and logistics to complex equipment like industrial robots make a wide use of

brushed and brushless DC motors (BLDC) and permanent magnet synchronous motor (PMSM)

BLDC motors and PMSMs are similarly structured both have permanent magnets (PM) in the rotor and are defined as synchronous motors

There are motors with different PM arrangements where the stator may have different numbers of windings and the rotor multiple pole pairs

However the way BLDC motors and PMSMs are controlled is very differentdue to the difference in the shape of their back EMF (electromotive force)

Rotor single pole pairStator three coils spaced at 120deg

12Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

When electrical motors are rotated a voltage is induced in the stator that opposes the driving voltage of the motor

Back EMF is an important characteristic as its shape dictates the kind of algorithm required to optimally control it

Due to their design BLDC motors have a trapezoidal back EMF and are controlled by trapezoidal commutation

BLDC

Trapezoidal Back EMF

Controlled by trapezoidal commutation

PMSM

Sinusoidal Back EMF

Controlled by field-oriented control

Six-Step Commutation (or Trapezoidal Control)

bull The coils which are here referred to as phases A B and C can be energized by passing a current through them

bull Applying voltage across two phases A and C (in the animation) generates a combined magnetic field along the dashed line The rotor turns to align itself with the stator magnetic field

13

BLDC Six-Step Commutation

bull There are six possible ways of energizing coil pairsBy commutating two phases at a time the resulting stator magnetic field is rotated

bull The rotor angle is measured with respect to the horizontal axis and there are six different rotor alignmentseach 60 degrees apart from each otherThis means that if the correct phases are commutated every 60 degrees the motor will continuously spin

Electrical MachinesDrives

From here the name six-step commutation (or trapezoidal control)

More pole pairs can be added to such machines requiring for the commutation to take place more often

bull 1 pole pair 60deg 2 pole pairs 30deg 4 pole-pairs 15deg

To properly commutate the motor at the right times with the correct phases the controller needs to know the exact position of the rotor at any time which is usually measured by using

Hall sensors

14

bull By adjusting the applied voltage is varied the motor speed

Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

To control the phases during six-step commutation a three-phase inverter is used to direct the DC power to the

three phases switching between positive (red) and negative (blue) current

To supply positive current to one of the phases the high side switch connected to that phase needs to be turned on

bull Doing this while the rotor is at an angle between 60 and 120degto the stator magnetic field the three-phase inverter keeps the motor rotating at a constant speed

15Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

From the control point of view the system has a dynamic behavior very similar to a (brushed) PM DC motor

(That is why is called BLDC)

used to compute the sector

T1T4 T1T6 T3T6 T3T2 T5T2 T5T4

Look-up table

speed calc

hall

BLDC

com

mu

tati

on

tab

le

16Electrical MachinesDrives

BLDC Six-Step Commutation vs PMSM

There are two reasons for switching phases in BLDC motors in Six-Step Commutation

If the rotor and stator magnetic fields were allowed to align perfectly the motor would create zero torque

Maximum torque occurs when the fields are at 90 degto each otherThe goal therefore is to bring this angle close to 90deg

Pros

simple nature of trapezoidal control

Cons

torquecurrent is quite noise due to the nature of the switching

sequence (ie two phases) losses and harmonic excitation

More advanced techniques such as field-oriented

control (FOC) commonly used to control PMSMs

allows generation of larger torques (by achieving 90deg

between the stator and rotor magnetic fields) and

lower harmonic content

17

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

18Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

Control Logic Power Stage

TI C2000 MCUs LaunchPad

TI BoosterPacks PMSM

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

7Past Present and Future Motion Control Systems

Future innovation in the development of motion control systems

Key components are today available with high performance

1st Option for gaining a competitive advantage further optimize the laquocomponentsraquo

eg Ultra-High Speed Machines Ultra-Efficient Converter

2nd Option for gaining a competitive advantage target specific mechatronic system needs

eg System level optimization and Integration (eg many servo drives)

Extremely Wide Application Areas

bull Machining

bull Handling and Assembly

bull Transportation (land sea air)

bull Gas Oil and Mining

bull Water Wastewater

bull Consumer Electronics

bull Computers

bull Home Appliances

bull Defense

bull Medical

bull Space Exploration

Compact amp EfficientPower Converter

High-Performance Mechanical Actuators

High-Performance MCU and SoC-based Platforms

Precision Sensors Wide Communication

Compact amp EfficientElectrical Machines

Component level

System level

8Past Present and Future Motion Control Systems

2nd Option for gaining a competitive advantage target specific mechatronic system needs

This is practically achieved by targeting the laquoSystem Levelraquoand have competences to bridge the boundaries between more (gt) than 3 key areas

This already represent the TODAY scenariohellip

Opens Path to Endless Product Innovation

Industrial automation

Source ETH Research Vectors in Power Electronics and Motion Control

9Industrial Automation

The industrial robot system case study

Low-level controlHigh-level control

All sub-systems must be optimized

decentralized

architecture

10

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

11Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

Machines ranging from devices like drills and logistics to complex equipment like industrial robots make a wide use of

brushed and brushless DC motors (BLDC) and permanent magnet synchronous motor (PMSM)

BLDC motors and PMSMs are similarly structured both have permanent magnets (PM) in the rotor and are defined as synchronous motors

There are motors with different PM arrangements where the stator may have different numbers of windings and the rotor multiple pole pairs

However the way BLDC motors and PMSMs are controlled is very differentdue to the difference in the shape of their back EMF (electromotive force)

Rotor single pole pairStator three coils spaced at 120deg

12Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

When electrical motors are rotated a voltage is induced in the stator that opposes the driving voltage of the motor

Back EMF is an important characteristic as its shape dictates the kind of algorithm required to optimally control it

Due to their design BLDC motors have a trapezoidal back EMF and are controlled by trapezoidal commutation

BLDC

Trapezoidal Back EMF

Controlled by trapezoidal commutation

PMSM

Sinusoidal Back EMF

Controlled by field-oriented control

Six-Step Commutation (or Trapezoidal Control)

bull The coils which are here referred to as phases A B and C can be energized by passing a current through them

bull Applying voltage across two phases A and C (in the animation) generates a combined magnetic field along the dashed line The rotor turns to align itself with the stator magnetic field

13

BLDC Six-Step Commutation

bull There are six possible ways of energizing coil pairsBy commutating two phases at a time the resulting stator magnetic field is rotated

bull The rotor angle is measured with respect to the horizontal axis and there are six different rotor alignmentseach 60 degrees apart from each otherThis means that if the correct phases are commutated every 60 degrees the motor will continuously spin

Electrical MachinesDrives

From here the name six-step commutation (or trapezoidal control)

More pole pairs can be added to such machines requiring for the commutation to take place more often

bull 1 pole pair 60deg 2 pole pairs 30deg 4 pole-pairs 15deg

To properly commutate the motor at the right times with the correct phases the controller needs to know the exact position of the rotor at any time which is usually measured by using

Hall sensors

14

bull By adjusting the applied voltage is varied the motor speed

Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

To control the phases during six-step commutation a three-phase inverter is used to direct the DC power to the

three phases switching between positive (red) and negative (blue) current

To supply positive current to one of the phases the high side switch connected to that phase needs to be turned on

bull Doing this while the rotor is at an angle between 60 and 120degto the stator magnetic field the three-phase inverter keeps the motor rotating at a constant speed

15Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

From the control point of view the system has a dynamic behavior very similar to a (brushed) PM DC motor

(That is why is called BLDC)

used to compute the sector

T1T4 T1T6 T3T6 T3T2 T5T2 T5T4

Look-up table

speed calc

hall

BLDC

com

mu

tati

on

tab

le

16Electrical MachinesDrives

BLDC Six-Step Commutation vs PMSM

There are two reasons for switching phases in BLDC motors in Six-Step Commutation

If the rotor and stator magnetic fields were allowed to align perfectly the motor would create zero torque

Maximum torque occurs when the fields are at 90 degto each otherThe goal therefore is to bring this angle close to 90deg

Pros

simple nature of trapezoidal control

Cons

torquecurrent is quite noise due to the nature of the switching

sequence (ie two phases) losses and harmonic excitation

More advanced techniques such as field-oriented

control (FOC) commonly used to control PMSMs

allows generation of larger torques (by achieving 90deg

between the stator and rotor magnetic fields) and

lower harmonic content

17

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

18Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

Control Logic Power Stage

TI C2000 MCUs LaunchPad

TI BoosterPacks PMSM

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

8Past Present and Future Motion Control Systems

2nd Option for gaining a competitive advantage target specific mechatronic system needs

This is practically achieved by targeting the laquoSystem Levelraquoand have competences to bridge the boundaries between more (gt) than 3 key areas

This already represent the TODAY scenariohellip

Opens Path to Endless Product Innovation

Industrial automation

Source ETH Research Vectors in Power Electronics and Motion Control

9Industrial Automation

The industrial robot system case study

Low-level controlHigh-level control

All sub-systems must be optimized

decentralized

architecture

10

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

11Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

Machines ranging from devices like drills and logistics to complex equipment like industrial robots make a wide use of

brushed and brushless DC motors (BLDC) and permanent magnet synchronous motor (PMSM)

BLDC motors and PMSMs are similarly structured both have permanent magnets (PM) in the rotor and are defined as synchronous motors

There are motors with different PM arrangements where the stator may have different numbers of windings and the rotor multiple pole pairs

However the way BLDC motors and PMSMs are controlled is very differentdue to the difference in the shape of their back EMF (electromotive force)

Rotor single pole pairStator three coils spaced at 120deg

12Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

When electrical motors are rotated a voltage is induced in the stator that opposes the driving voltage of the motor

Back EMF is an important characteristic as its shape dictates the kind of algorithm required to optimally control it

Due to their design BLDC motors have a trapezoidal back EMF and are controlled by trapezoidal commutation

BLDC

Trapezoidal Back EMF

Controlled by trapezoidal commutation

PMSM

Sinusoidal Back EMF

Controlled by field-oriented control

Six-Step Commutation (or Trapezoidal Control)

bull The coils which are here referred to as phases A B and C can be energized by passing a current through them

bull Applying voltage across two phases A and C (in the animation) generates a combined magnetic field along the dashed line The rotor turns to align itself with the stator magnetic field

13

BLDC Six-Step Commutation

bull There are six possible ways of energizing coil pairsBy commutating two phases at a time the resulting stator magnetic field is rotated

bull The rotor angle is measured with respect to the horizontal axis and there are six different rotor alignmentseach 60 degrees apart from each otherThis means that if the correct phases are commutated every 60 degrees the motor will continuously spin

Electrical MachinesDrives

From here the name six-step commutation (or trapezoidal control)

More pole pairs can be added to such machines requiring for the commutation to take place more often

bull 1 pole pair 60deg 2 pole pairs 30deg 4 pole-pairs 15deg

To properly commutate the motor at the right times with the correct phases the controller needs to know the exact position of the rotor at any time which is usually measured by using

Hall sensors

14

bull By adjusting the applied voltage is varied the motor speed

Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

To control the phases during six-step commutation a three-phase inverter is used to direct the DC power to the

three phases switching between positive (red) and negative (blue) current

To supply positive current to one of the phases the high side switch connected to that phase needs to be turned on

bull Doing this while the rotor is at an angle between 60 and 120degto the stator magnetic field the three-phase inverter keeps the motor rotating at a constant speed

15Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

From the control point of view the system has a dynamic behavior very similar to a (brushed) PM DC motor

(That is why is called BLDC)

used to compute the sector

T1T4 T1T6 T3T6 T3T2 T5T2 T5T4

Look-up table

speed calc

hall

BLDC

com

mu

tati

on

tab

le

16Electrical MachinesDrives

BLDC Six-Step Commutation vs PMSM

There are two reasons for switching phases in BLDC motors in Six-Step Commutation

If the rotor and stator magnetic fields were allowed to align perfectly the motor would create zero torque

Maximum torque occurs when the fields are at 90 degto each otherThe goal therefore is to bring this angle close to 90deg

Pros

simple nature of trapezoidal control

Cons

torquecurrent is quite noise due to the nature of the switching

sequence (ie two phases) losses and harmonic excitation

More advanced techniques such as field-oriented

control (FOC) commonly used to control PMSMs

allows generation of larger torques (by achieving 90deg

between the stator and rotor magnetic fields) and

lower harmonic content

17

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

18Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

Control Logic Power Stage

TI C2000 MCUs LaunchPad

TI BoosterPacks PMSM

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

9Industrial Automation

The industrial robot system case study

Low-level controlHigh-level control

All sub-systems must be optimized

decentralized

architecture

10

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

11Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

Machines ranging from devices like drills and logistics to complex equipment like industrial robots make a wide use of

brushed and brushless DC motors (BLDC) and permanent magnet synchronous motor (PMSM)

BLDC motors and PMSMs are similarly structured both have permanent magnets (PM) in the rotor and are defined as synchronous motors

There are motors with different PM arrangements where the stator may have different numbers of windings and the rotor multiple pole pairs

However the way BLDC motors and PMSMs are controlled is very differentdue to the difference in the shape of their back EMF (electromotive force)

Rotor single pole pairStator three coils spaced at 120deg

12Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

When electrical motors are rotated a voltage is induced in the stator that opposes the driving voltage of the motor

Back EMF is an important characteristic as its shape dictates the kind of algorithm required to optimally control it

Due to their design BLDC motors have a trapezoidal back EMF and are controlled by trapezoidal commutation

BLDC

Trapezoidal Back EMF

Controlled by trapezoidal commutation

PMSM

Sinusoidal Back EMF

Controlled by field-oriented control

Six-Step Commutation (or Trapezoidal Control)

bull The coils which are here referred to as phases A B and C can be energized by passing a current through them

bull Applying voltage across two phases A and C (in the animation) generates a combined magnetic field along the dashed line The rotor turns to align itself with the stator magnetic field

13

BLDC Six-Step Commutation

bull There are six possible ways of energizing coil pairsBy commutating two phases at a time the resulting stator magnetic field is rotated

bull The rotor angle is measured with respect to the horizontal axis and there are six different rotor alignmentseach 60 degrees apart from each otherThis means that if the correct phases are commutated every 60 degrees the motor will continuously spin

Electrical MachinesDrives

From here the name six-step commutation (or trapezoidal control)

More pole pairs can be added to such machines requiring for the commutation to take place more often

bull 1 pole pair 60deg 2 pole pairs 30deg 4 pole-pairs 15deg

To properly commutate the motor at the right times with the correct phases the controller needs to know the exact position of the rotor at any time which is usually measured by using

Hall sensors

14

bull By adjusting the applied voltage is varied the motor speed

Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

To control the phases during six-step commutation a three-phase inverter is used to direct the DC power to the

three phases switching between positive (red) and negative (blue) current

To supply positive current to one of the phases the high side switch connected to that phase needs to be turned on

bull Doing this while the rotor is at an angle between 60 and 120degto the stator magnetic field the three-phase inverter keeps the motor rotating at a constant speed

15Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

From the control point of view the system has a dynamic behavior very similar to a (brushed) PM DC motor

(That is why is called BLDC)

used to compute the sector

T1T4 T1T6 T3T6 T3T2 T5T2 T5T4

Look-up table

speed calc

hall

BLDC

com

mu

tati

on

tab

le

16Electrical MachinesDrives

BLDC Six-Step Commutation vs PMSM

There are two reasons for switching phases in BLDC motors in Six-Step Commutation

If the rotor and stator magnetic fields were allowed to align perfectly the motor would create zero torque

Maximum torque occurs when the fields are at 90 degto each otherThe goal therefore is to bring this angle close to 90deg

Pros

simple nature of trapezoidal control

Cons

torquecurrent is quite noise due to the nature of the switching

sequence (ie two phases) losses and harmonic excitation

More advanced techniques such as field-oriented

control (FOC) commonly used to control PMSMs

allows generation of larger torques (by achieving 90deg

between the stator and rotor magnetic fields) and

lower harmonic content

17

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

18Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

Control Logic Power Stage

TI C2000 MCUs LaunchPad

TI BoosterPacks PMSM

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

10

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

11Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

Machines ranging from devices like drills and logistics to complex equipment like industrial robots make a wide use of

brushed and brushless DC motors (BLDC) and permanent magnet synchronous motor (PMSM)

BLDC motors and PMSMs are similarly structured both have permanent magnets (PM) in the rotor and are defined as synchronous motors

There are motors with different PM arrangements where the stator may have different numbers of windings and the rotor multiple pole pairs

However the way BLDC motors and PMSMs are controlled is very differentdue to the difference in the shape of their back EMF (electromotive force)

Rotor single pole pairStator three coils spaced at 120deg

12Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

When electrical motors are rotated a voltage is induced in the stator that opposes the driving voltage of the motor

Back EMF is an important characteristic as its shape dictates the kind of algorithm required to optimally control it

Due to their design BLDC motors have a trapezoidal back EMF and are controlled by trapezoidal commutation

BLDC

Trapezoidal Back EMF

Controlled by trapezoidal commutation

PMSM

Sinusoidal Back EMF

Controlled by field-oriented control

Six-Step Commutation (or Trapezoidal Control)

bull The coils which are here referred to as phases A B and C can be energized by passing a current through them

bull Applying voltage across two phases A and C (in the animation) generates a combined magnetic field along the dashed line The rotor turns to align itself with the stator magnetic field

13

BLDC Six-Step Commutation

bull There are six possible ways of energizing coil pairsBy commutating two phases at a time the resulting stator magnetic field is rotated

bull The rotor angle is measured with respect to the horizontal axis and there are six different rotor alignmentseach 60 degrees apart from each otherThis means that if the correct phases are commutated every 60 degrees the motor will continuously spin

Electrical MachinesDrives

From here the name six-step commutation (or trapezoidal control)

More pole pairs can be added to such machines requiring for the commutation to take place more often

bull 1 pole pair 60deg 2 pole pairs 30deg 4 pole-pairs 15deg

To properly commutate the motor at the right times with the correct phases the controller needs to know the exact position of the rotor at any time which is usually measured by using

Hall sensors

14

bull By adjusting the applied voltage is varied the motor speed

Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

To control the phases during six-step commutation a three-phase inverter is used to direct the DC power to the

three phases switching between positive (red) and negative (blue) current

To supply positive current to one of the phases the high side switch connected to that phase needs to be turned on

bull Doing this while the rotor is at an angle between 60 and 120degto the stator magnetic field the three-phase inverter keeps the motor rotating at a constant speed

15Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

From the control point of view the system has a dynamic behavior very similar to a (brushed) PM DC motor

(That is why is called BLDC)

used to compute the sector

T1T4 T1T6 T3T6 T3T2 T5T2 T5T4

Look-up table

speed calc

hall

BLDC

com

mu

tati

on

tab

le

16Electrical MachinesDrives

BLDC Six-Step Commutation vs PMSM

There are two reasons for switching phases in BLDC motors in Six-Step Commutation

If the rotor and stator magnetic fields were allowed to align perfectly the motor would create zero torque

Maximum torque occurs when the fields are at 90 degto each otherThe goal therefore is to bring this angle close to 90deg

Pros

simple nature of trapezoidal control

Cons

torquecurrent is quite noise due to the nature of the switching

sequence (ie two phases) losses and harmonic excitation

More advanced techniques such as field-oriented

control (FOC) commonly used to control PMSMs

allows generation of larger torques (by achieving 90deg

between the stator and rotor magnetic fields) and

lower harmonic content

17

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

18Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

Control Logic Power Stage

TI C2000 MCUs LaunchPad

TI BoosterPacks PMSM

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

11Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

Machines ranging from devices like drills and logistics to complex equipment like industrial robots make a wide use of

brushed and brushless DC motors (BLDC) and permanent magnet synchronous motor (PMSM)

BLDC motors and PMSMs are similarly structured both have permanent magnets (PM) in the rotor and are defined as synchronous motors

There are motors with different PM arrangements where the stator may have different numbers of windings and the rotor multiple pole pairs

However the way BLDC motors and PMSMs are controlled is very differentdue to the difference in the shape of their back EMF (electromotive force)

Rotor single pole pairStator three coils spaced at 120deg

12Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

When electrical motors are rotated a voltage is induced in the stator that opposes the driving voltage of the motor

Back EMF is an important characteristic as its shape dictates the kind of algorithm required to optimally control it

Due to their design BLDC motors have a trapezoidal back EMF and are controlled by trapezoidal commutation

BLDC

Trapezoidal Back EMF

Controlled by trapezoidal commutation

PMSM

Sinusoidal Back EMF

Controlled by field-oriented control

Six-Step Commutation (or Trapezoidal Control)

bull The coils which are here referred to as phases A B and C can be energized by passing a current through them

bull Applying voltage across two phases A and C (in the animation) generates a combined magnetic field along the dashed line The rotor turns to align itself with the stator magnetic field

13

BLDC Six-Step Commutation

bull There are six possible ways of energizing coil pairsBy commutating two phases at a time the resulting stator magnetic field is rotated

bull The rotor angle is measured with respect to the horizontal axis and there are six different rotor alignmentseach 60 degrees apart from each otherThis means that if the correct phases are commutated every 60 degrees the motor will continuously spin

Electrical MachinesDrives

From here the name six-step commutation (or trapezoidal control)

More pole pairs can be added to such machines requiring for the commutation to take place more often

bull 1 pole pair 60deg 2 pole pairs 30deg 4 pole-pairs 15deg

To properly commutate the motor at the right times with the correct phases the controller needs to know the exact position of the rotor at any time which is usually measured by using

Hall sensors

14

bull By adjusting the applied voltage is varied the motor speed

Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

To control the phases during six-step commutation a three-phase inverter is used to direct the DC power to the

three phases switching between positive (red) and negative (blue) current

To supply positive current to one of the phases the high side switch connected to that phase needs to be turned on

bull Doing this while the rotor is at an angle between 60 and 120degto the stator magnetic field the three-phase inverter keeps the motor rotating at a constant speed

15Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

From the control point of view the system has a dynamic behavior very similar to a (brushed) PM DC motor

(That is why is called BLDC)

used to compute the sector

T1T4 T1T6 T3T6 T3T2 T5T2 T5T4

Look-up table

speed calc

hall

BLDC

com

mu

tati

on

tab

le

16Electrical MachinesDrives

BLDC Six-Step Commutation vs PMSM

There are two reasons for switching phases in BLDC motors in Six-Step Commutation

If the rotor and stator magnetic fields were allowed to align perfectly the motor would create zero torque

Maximum torque occurs when the fields are at 90 degto each otherThe goal therefore is to bring this angle close to 90deg

Pros

simple nature of trapezoidal control

Cons

torquecurrent is quite noise due to the nature of the switching

sequence (ie two phases) losses and harmonic excitation

More advanced techniques such as field-oriented

control (FOC) commonly used to control PMSMs

allows generation of larger torques (by achieving 90deg

between the stator and rotor magnetic fields) and

lower harmonic content

17

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

18Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

Control Logic Power Stage

TI C2000 MCUs LaunchPad

TI BoosterPacks PMSM

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

12Electrical MachinesDrives

Servo motorsServo drives in Industrial Automation

When electrical motors are rotated a voltage is induced in the stator that opposes the driving voltage of the motor

Back EMF is an important characteristic as its shape dictates the kind of algorithm required to optimally control it

Due to their design BLDC motors have a trapezoidal back EMF and are controlled by trapezoidal commutation

BLDC

Trapezoidal Back EMF

Controlled by trapezoidal commutation

PMSM

Sinusoidal Back EMF

Controlled by field-oriented control

Six-Step Commutation (or Trapezoidal Control)

bull The coils which are here referred to as phases A B and C can be energized by passing a current through them

bull Applying voltage across two phases A and C (in the animation) generates a combined magnetic field along the dashed line The rotor turns to align itself with the stator magnetic field

13

BLDC Six-Step Commutation

bull There are six possible ways of energizing coil pairsBy commutating two phases at a time the resulting stator magnetic field is rotated

bull The rotor angle is measured with respect to the horizontal axis and there are six different rotor alignmentseach 60 degrees apart from each otherThis means that if the correct phases are commutated every 60 degrees the motor will continuously spin

Electrical MachinesDrives

From here the name six-step commutation (or trapezoidal control)

More pole pairs can be added to such machines requiring for the commutation to take place more often

bull 1 pole pair 60deg 2 pole pairs 30deg 4 pole-pairs 15deg

To properly commutate the motor at the right times with the correct phases the controller needs to know the exact position of the rotor at any time which is usually measured by using

Hall sensors

14

bull By adjusting the applied voltage is varied the motor speed

Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

To control the phases during six-step commutation a three-phase inverter is used to direct the DC power to the

three phases switching between positive (red) and negative (blue) current

To supply positive current to one of the phases the high side switch connected to that phase needs to be turned on

bull Doing this while the rotor is at an angle between 60 and 120degto the stator magnetic field the three-phase inverter keeps the motor rotating at a constant speed

15Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

From the control point of view the system has a dynamic behavior very similar to a (brushed) PM DC motor

(That is why is called BLDC)

used to compute the sector

T1T4 T1T6 T3T6 T3T2 T5T2 T5T4

Look-up table

speed calc

hall

BLDC

com

mu

tati

on

tab

le

16Electrical MachinesDrives

BLDC Six-Step Commutation vs PMSM

There are two reasons for switching phases in BLDC motors in Six-Step Commutation

If the rotor and stator magnetic fields were allowed to align perfectly the motor would create zero torque

Maximum torque occurs when the fields are at 90 degto each otherThe goal therefore is to bring this angle close to 90deg

Pros

simple nature of trapezoidal control

Cons

torquecurrent is quite noise due to the nature of the switching

sequence (ie two phases) losses and harmonic excitation

More advanced techniques such as field-oriented

control (FOC) commonly used to control PMSMs

allows generation of larger torques (by achieving 90deg

between the stator and rotor magnetic fields) and

lower harmonic content

17

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

18Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

Control Logic Power Stage

TI C2000 MCUs LaunchPad

TI BoosterPacks PMSM

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

13

BLDC Six-Step Commutation

bull There are six possible ways of energizing coil pairsBy commutating two phases at a time the resulting stator magnetic field is rotated

bull The rotor angle is measured with respect to the horizontal axis and there are six different rotor alignmentseach 60 degrees apart from each otherThis means that if the correct phases are commutated every 60 degrees the motor will continuously spin

Electrical MachinesDrives

From here the name six-step commutation (or trapezoidal control)

More pole pairs can be added to such machines requiring for the commutation to take place more often

bull 1 pole pair 60deg 2 pole pairs 30deg 4 pole-pairs 15deg

To properly commutate the motor at the right times with the correct phases the controller needs to know the exact position of the rotor at any time which is usually measured by using

Hall sensors

14

bull By adjusting the applied voltage is varied the motor speed

Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

To control the phases during six-step commutation a three-phase inverter is used to direct the DC power to the

three phases switching between positive (red) and negative (blue) current

To supply positive current to one of the phases the high side switch connected to that phase needs to be turned on

bull Doing this while the rotor is at an angle between 60 and 120degto the stator magnetic field the three-phase inverter keeps the motor rotating at a constant speed

15Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

From the control point of view the system has a dynamic behavior very similar to a (brushed) PM DC motor

(That is why is called BLDC)

used to compute the sector

T1T4 T1T6 T3T6 T3T2 T5T2 T5T4

Look-up table

speed calc

hall

BLDC

com

mu

tati

on

tab

le

16Electrical MachinesDrives

BLDC Six-Step Commutation vs PMSM

There are two reasons for switching phases in BLDC motors in Six-Step Commutation

If the rotor and stator magnetic fields were allowed to align perfectly the motor would create zero torque

Maximum torque occurs when the fields are at 90 degto each otherThe goal therefore is to bring this angle close to 90deg

Pros

simple nature of trapezoidal control

Cons

torquecurrent is quite noise due to the nature of the switching

sequence (ie two phases) losses and harmonic excitation

More advanced techniques such as field-oriented

control (FOC) commonly used to control PMSMs

allows generation of larger torques (by achieving 90deg

between the stator and rotor magnetic fields) and

lower harmonic content

17

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

18Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

Control Logic Power Stage

TI C2000 MCUs LaunchPad

TI BoosterPacks PMSM

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

14

bull By adjusting the applied voltage is varied the motor speed

Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

To control the phases during six-step commutation a three-phase inverter is used to direct the DC power to the

three phases switching between positive (red) and negative (blue) current

To supply positive current to one of the phases the high side switch connected to that phase needs to be turned on

bull Doing this while the rotor is at an angle between 60 and 120degto the stator magnetic field the three-phase inverter keeps the motor rotating at a constant speed

15Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

From the control point of view the system has a dynamic behavior very similar to a (brushed) PM DC motor

(That is why is called BLDC)

used to compute the sector

T1T4 T1T6 T3T6 T3T2 T5T2 T5T4

Look-up table

speed calc

hall

BLDC

com

mu

tati

on

tab

le

16Electrical MachinesDrives

BLDC Six-Step Commutation vs PMSM

There are two reasons for switching phases in BLDC motors in Six-Step Commutation

If the rotor and stator magnetic fields were allowed to align perfectly the motor would create zero torque

Maximum torque occurs when the fields are at 90 degto each otherThe goal therefore is to bring this angle close to 90deg

Pros

simple nature of trapezoidal control

Cons

torquecurrent is quite noise due to the nature of the switching

sequence (ie two phases) losses and harmonic excitation

More advanced techniques such as field-oriented

control (FOC) commonly used to control PMSMs

allows generation of larger torques (by achieving 90deg

between the stator and rotor magnetic fields) and

lower harmonic content

17

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

18Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

Control Logic Power Stage

TI C2000 MCUs LaunchPad

TI BoosterPacks PMSM

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

15Electrical MachinesDrives

BLDC Six-Step Commutation (in Practice)

From the control point of view the system has a dynamic behavior very similar to a (brushed) PM DC motor

(That is why is called BLDC)

used to compute the sector

T1T4 T1T6 T3T6 T3T2 T5T2 T5T4

Look-up table

speed calc

hall

BLDC

com

mu

tati

on

tab

le

16Electrical MachinesDrives

BLDC Six-Step Commutation vs PMSM

There are two reasons for switching phases in BLDC motors in Six-Step Commutation

If the rotor and stator magnetic fields were allowed to align perfectly the motor would create zero torque

Maximum torque occurs when the fields are at 90 degto each otherThe goal therefore is to bring this angle close to 90deg

Pros

simple nature of trapezoidal control

Cons

torquecurrent is quite noise due to the nature of the switching

sequence (ie two phases) losses and harmonic excitation

More advanced techniques such as field-oriented

control (FOC) commonly used to control PMSMs

allows generation of larger torques (by achieving 90deg

between the stator and rotor magnetic fields) and

lower harmonic content

17

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

18Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

Control Logic Power Stage

TI C2000 MCUs LaunchPad

TI BoosterPacks PMSM

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

16Electrical MachinesDrives

BLDC Six-Step Commutation vs PMSM

There are two reasons for switching phases in BLDC motors in Six-Step Commutation

If the rotor and stator magnetic fields were allowed to align perfectly the motor would create zero torque

Maximum torque occurs when the fields are at 90 degto each otherThe goal therefore is to bring this angle close to 90deg

Pros

simple nature of trapezoidal control

Cons

torquecurrent is quite noise due to the nature of the switching

sequence (ie two phases) losses and harmonic excitation

More advanced techniques such as field-oriented

control (FOC) commonly used to control PMSMs

allows generation of larger torques (by achieving 90deg

between the stator and rotor magnetic fields) and

lower harmonic content

17

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

18Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

Control Logic Power Stage

TI C2000 MCUs LaunchPad

TI BoosterPacks PMSM

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

17

Motion Control Systems

Control of Electrical Drives

How can you move from motor control theory to practiceWhere implement the control logic

18Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

Control Logic Power Stage

TI C2000 MCUs LaunchPad

TI BoosterPacks PMSM

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

18Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

Control Logic Power Stage

TI C2000 MCUs LaunchPad

TI BoosterPacks PMSM

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

19

The TI C2000 LaunchPad MCUs are low cost easy-to-use development boards with rapid prototpying capabilities

Industrial Automation (pt2)

Let consider a FOC for a PMSM since it presents a greater computational complexity

The control scheme must be translated in laquoroutinesraquo suitable for MCU and laquofeedbackraquo available at the MCU

How it looks in practice

3-ph terminals

PMSM

DRV8301

F28069M

Analog inputs(User interface)

measurements

How the firmware is developed

PMSM

dc-link

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

20How to Program MCUs main approaches

MCUs ldquoshouldrdquo be programmed via machine code to execute customized routines defined by the user

peripherals must be correctly set uphellipthis is time expensive (and quite often an obstacle for rookies)

Today there are different alternatives and tools which can simplify the implementation

Letrsquos consider two of them

CC++ programming

use an IDE (eg Code Composer Studio) to write C-code(compile link download link debug)

Automatic Code GenerationRapid Prototyping

use an interface (eg MATLABSimulink) to create high-level code(translate compile link download link debug)

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

21MathWorks Rapid Prototyping Approach for TI C2000

+

Texas Instruments

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

Start motor type speedtorque profile power rating voltagecurrent limits

embedded hardware

TI F28069M

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

22MathWorks Rapid Prototyping Approach for TI C2000

Workflow (guidelines) to design a firmware with Simulink rapid prototyping

we refer to a blockset library

but not all MCUs are supported ()

all pheripherals should be laquo known raquoand charaterized in Simulink blocks

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

23

This specific workflow requires the usage of different softwarepackages

Install

Code Composer Studio Vx (where x is related to the MATLAB release) - (IDE)

ControlSUITE Vx - (repository containg the board know how eg peripheral settingsregistersexamples)

Given that Simulink will use

Embedded Coder for TI C2000 Processors (Add Ons)

Which is a sort of toolbox that

load the blockset library for the supported board

make available a toolchain which work in background with Code Composer Studio Vx to compile the resulting block scheme and generate C code from 8bit to multi-core MCUs

Additional features

bull Code optimization (processor-specifc)

bull Code verification (PILhellip)

bull Code profiling (tasks routinehellip)

bull Code optimization (functions fileshellip)

bull Embedded targets (boards schedulerhellip)

MathWorks Rapid Prototyping Approach for TI C2000

what you see

what happens beyondIt generates (ANSIISO C) by default

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

24MathWorks Rapid Prototyping Approach for TI C2000

How it looks like

tested by PoliMi up to MATLAB 2020b

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

25

Different ready-to use test benches for the study of power electronics and motor control applications are available

The team of Politecnico di Milano in collaboration with Texas Instruments Wurth Elektronik and MathWorks

developed MCU-based Hardware kits with full support to TI C2000 Piccolo and Delfino families

the programming approach can be either via MATLABSimulink or C programming

MCU-based Hardware Kits

RL(C) kit which integrates the extRL(C) board with the LaunchPadtrade F28069M and the BOOSTXL DRV8301 boards

B2B-PMDC kit which contains two coupled PMDC motors anchored on an aluminum base plate encoder sensor and MCU interface for external power supply

B2B-BLDC kit which contains a PMDC motor and a BLDC motor coupled anchored on an aluminum base plate encoder sensor

and MCU interface for external power supply

The exercises are collected in the book

Introduction to Microcontroller Programming for Power Electronics Control Applicationsldquo MRossi NToscani MMauri FCastelli-Dezza (CRC press)

available from September 2021

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

26

Those kits represent full standalone solutionshellipchoosen according to what has to be tested

Please contact Prof Francesco Castelli-Dezza or Ing Mattia Rossi if you have further interests

francescocastellidezzapolimiit marcomauripolimiit matteo1spositopolimiitmattiarossipolimiit nicolatoscanipolimiit andreapolastripolimiit

MCU-based Hardware Kits

Developed in collaboration withDesigned by Distributed by

27Example B2B configuration BLDC + DC Motors

Implementation point of view

The B2B-BLDC kit includes a BLDCAC motor with Hall sensor which can be used to implement eithertrapezoidal control or FOC via Simulink workflow

The brushed DC motor may be used to actively braking the BLDC motor in order to

exploit the operating region

estimate an efficiency map for the motor

bull back-to-back configuration

bull one LaunchPadtrade F28069M board

bull one or two Boosterpack TItrade BOOSTXL-DRV8301 converter boards

bull one extPot3 board

bull a mezzanine board to hold the MCU and manage the external power supply

bull one BLDC motor with Hall sensors

bull one PMDC motor

bull encoder LPD3806-600BM-G5-24C

PMDC motor

encoder

extPot3 boardBOOSTXL-DRV8301 LaunchPadtrade F28069M

BLDC motor

28Example B2B configuration Brushed DC Motors

Implementation point of view

The B2B-PMDC kit includes two brushed DC motors which can be operated in half-bridge or H-bridge configuration with the control implemented via Simulink workflow

One of the brushed DC motor may be used to actively braking the BLDC motor in order to

exploit the operating region

estimate an efficiency map for the motor

bull back-to-back configuration

bull one LaunchPadtrade F28069M board

bull one or two Boosterpack TItrade BOOSTXL-DRV8301 converter boards

bull one extPot3 board

bull a mezzanine board to hold the MCU and manage the external power supply

bull two equal PMDC motors

bull encoder LPD3806-600BM-G5-24C

PMDC motors encoder

extPot3 boardBOOSTXL-DRV8301 LaunchPadtrade F28069M

29Example B2B configuration Brushed DC Motors

Implementation Cascade Speed Control (half-bridge) + torquecurrent control loop (half-bridge)

Let assume a step-wise speed reference to test if the implemented logic works fine

30Example B2B configuration Brushed DC Motors

Implementation Cascade Speed Control (half-bridge) + torquecurrent control loop (half-bridge)

Let assume a step-wise speed reference to test if the implemented logic works fine

pay attention to currentvoltage saturations include anti wind-up and integral reset

what happens to currentvoltage if we apply a load torque at steady state

cascade speed control works fine

31

Less work for field operators (technical)

More work for researcher (technical)

Better time-to-market for new releasesplatforms (economical)

target specific mechatronic system needs is practically achieved by targeting the laquoSystem Levelraquoand have competences to bridge the boundaries between more (gt) than 3 key areas

In terms of control goals does it relates to

bull can I get more power

bull can I get faster dynamics

No itrsquos not about ldquopurerdquo better performances

Conclusions

Combining feedbackfeedforward structure (still classic linear theory)

we can operate servo drives at their physical limits

The real control goal is helliphellip simpler handling

Add greater intelligence on the controller in order to face by itself nonlinearities constraints delays model

mismatch

PI controllers behave like classical soldiers stereotype execute orders without laquothinkingraquo

32End Credits

Mattia Rossi

mattiarossipolimiit

Thanks for your attention

Credits to

Nicola Toscani Francesco Castelli Dezza Marco MauriMatteo Sposito Andrea Polastri Luca Grittini Alessandro Grittini

and ePEBBs srl

Politecnico di MilanoDepartment of Mechanical Engineering via La Masa 1 Milan 20156 ItalyElectrical Machines Drives and Power Electronics Research Group

28Example B2B configuration Brushed DC Motors

Implementation point of view

The B2B-PMDC kit includes two brushed DC motors which can be operated in half-bridge or H-bridge configuration with the control implemented via Simulink workflow

One of the brushed DC motor may be used to actively braking the BLDC motor in order to

exploit the operating region

estimate an efficiency map for the motor

bull back-to-back configuration

bull one LaunchPadtrade F28069M board

bull one or two Boosterpack TItrade BOOSTXL-DRV8301 converter boards

bull one extPot3 board

bull a mezzanine board to hold the MCU and manage the external power supply

bull two equal PMDC motors

bull encoder LPD3806-600BM-G5-24C

PMDC motors encoder

extPot3 boardBOOSTXL-DRV8301 LaunchPadtrade F28069M

29Example B2B configuration Brushed DC Motors

Implementation Cascade Speed Control (half-bridge) + torquecurrent control loop (half-bridge)

Let assume a step-wise speed reference to test if the implemented logic works fine

30Example B2B configuration Brushed DC Motors

Implementation Cascade Speed Control (half-bridge) + torquecurrent control loop (half-bridge)

Let assume a step-wise speed reference to test if the implemented logic works fine

pay attention to currentvoltage saturations include anti wind-up and integral reset

what happens to currentvoltage if we apply a load torque at steady state

cascade speed control works fine

31

Less work for field operators (technical)

More work for researcher (technical)

Better time-to-market for new releasesplatforms (economical)

target specific mechatronic system needs is practically achieved by targeting the laquoSystem Levelraquoand have competences to bridge the boundaries between more (gt) than 3 key areas

In terms of control goals does it relates to

bull can I get more power

bull can I get faster dynamics

No itrsquos not about ldquopurerdquo better performances

Conclusions

Combining feedbackfeedforward structure (still classic linear theory)

we can operate servo drives at their physical limits

The real control goal is helliphellip simpler handling

Add greater intelligence on the controller in order to face by itself nonlinearities constraints delays model

mismatch

PI controllers behave like classical soldiers stereotype execute orders without laquothinkingraquo

32End Credits

Mattia Rossi

mattiarossipolimiit

Thanks for your attention

Credits to

Nicola Toscani Francesco Castelli Dezza Marco MauriMatteo Sposito Andrea Polastri Luca Grittini Alessandro Grittini

and ePEBBs srl

Politecnico di MilanoDepartment of Mechanical Engineering via La Masa 1 Milan 20156 ItalyElectrical Machines Drives and Power Electronics Research Group

29Example B2B configuration Brushed DC Motors

Implementation Cascade Speed Control (half-bridge) + torquecurrent control loop (half-bridge)

Let assume a step-wise speed reference to test if the implemented logic works fine

30Example B2B configuration Brushed DC Motors

Implementation Cascade Speed Control (half-bridge) + torquecurrent control loop (half-bridge)

Let assume a step-wise speed reference to test if the implemented logic works fine

pay attention to currentvoltage saturations include anti wind-up and integral reset

what happens to currentvoltage if we apply a load torque at steady state

cascade speed control works fine

31

Less work for field operators (technical)

More work for researcher (technical)

Better time-to-market for new releasesplatforms (economical)

target specific mechatronic system needs is practically achieved by targeting the laquoSystem Levelraquoand have competences to bridge the boundaries between more (gt) than 3 key areas

In terms of control goals does it relates to

bull can I get more power

bull can I get faster dynamics

No itrsquos not about ldquopurerdquo better performances

Conclusions

Combining feedbackfeedforward structure (still classic linear theory)

we can operate servo drives at their physical limits

The real control goal is helliphellip simpler handling

Add greater intelligence on the controller in order to face by itself nonlinearities constraints delays model

mismatch

PI controllers behave like classical soldiers stereotype execute orders without laquothinkingraquo

32End Credits

Mattia Rossi

mattiarossipolimiit

Thanks for your attention

Credits to

Nicola Toscani Francesco Castelli Dezza Marco MauriMatteo Sposito Andrea Polastri Luca Grittini Alessandro Grittini

and ePEBBs srl

Politecnico di MilanoDepartment of Mechanical Engineering via La Masa 1 Milan 20156 ItalyElectrical Machines Drives and Power Electronics Research Group

30Example B2B configuration Brushed DC Motors

Implementation Cascade Speed Control (half-bridge) + torquecurrent control loop (half-bridge)

Let assume a step-wise speed reference to test if the implemented logic works fine

pay attention to currentvoltage saturations include anti wind-up and integral reset

what happens to currentvoltage if we apply a load torque at steady state

cascade speed control works fine

31

Less work for field operators (technical)

More work for researcher (technical)

Better time-to-market for new releasesplatforms (economical)

target specific mechatronic system needs is practically achieved by targeting the laquoSystem Levelraquoand have competences to bridge the boundaries between more (gt) than 3 key areas

In terms of control goals does it relates to

bull can I get more power

bull can I get faster dynamics

No itrsquos not about ldquopurerdquo better performances

Conclusions

Combining feedbackfeedforward structure (still classic linear theory)

we can operate servo drives at their physical limits

The real control goal is helliphellip simpler handling

Add greater intelligence on the controller in order to face by itself nonlinearities constraints delays model

mismatch

PI controllers behave like classical soldiers stereotype execute orders without laquothinkingraquo

32End Credits

Mattia Rossi

mattiarossipolimiit

Thanks for your attention

Credits to

Nicola Toscani Francesco Castelli Dezza Marco MauriMatteo Sposito Andrea Polastri Luca Grittini Alessandro Grittini

and ePEBBs srl

Politecnico di MilanoDepartment of Mechanical Engineering via La Masa 1 Milan 20156 ItalyElectrical Machines Drives and Power Electronics Research Group

31

Less work for field operators (technical)

More work for researcher (technical)

Better time-to-market for new releasesplatforms (economical)

target specific mechatronic system needs is practically achieved by targeting the laquoSystem Levelraquoand have competences to bridge the boundaries between more (gt) than 3 key areas

In terms of control goals does it relates to

bull can I get more power

bull can I get faster dynamics

No itrsquos not about ldquopurerdquo better performances

Conclusions

Combining feedbackfeedforward structure (still classic linear theory)

we can operate servo drives at their physical limits

The real control goal is helliphellip simpler handling

Add greater intelligence on the controller in order to face by itself nonlinearities constraints delays model

mismatch

PI controllers behave like classical soldiers stereotype execute orders without laquothinkingraquo

32End Credits

Mattia Rossi

mattiarossipolimiit

Thanks for your attention

Credits to

Nicola Toscani Francesco Castelli Dezza Marco MauriMatteo Sposito Andrea Polastri Luca Grittini Alessandro Grittini

and ePEBBs srl

Politecnico di MilanoDepartment of Mechanical Engineering via La Masa 1 Milan 20156 ItalyElectrical Machines Drives and Power Electronics Research Group

32End Credits

Mattia Rossi

mattiarossipolimiit

Thanks for your attention

Credits to

Nicola Toscani Francesco Castelli Dezza Marco MauriMatteo Sposito Andrea Polastri Luca Grittini Alessandro Grittini

and ePEBBs srl

Politecnico di MilanoDepartment of Mechanical Engineering via La Masa 1 Milan 20156 ItalyElectrical Machines Drives and Power Electronics Research Group