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TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLink and VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
FTF-AUT-F0737
MCU Solutions for Hybrid Drive TrainJune, 2010
Leos Chalupa, Ph.D.Freescale System Solution Engineer – El. Powertrain
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Session Objectives
►After completing this session you will be able to: • List the main areas of HEV application that are affected by
microcontroller selection• Understand the importance of functional safety for the application• Know the Freescale solution based on latest el. powertrain dedicated
microcontrollers
2
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 33
Agenda
►HEV System Overview
►MCU System Impacts• Main HEV component size,
weight, packaging
• Functional safety
►Freescale Advanced Solutions
• Device main functionality
• Functional safety
TM
HEV System Overview
4
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 55
Typical Hybrid System
• High efficiency gas engine• Planetary gear power split device
AC synchronous generator• High voltage AC-DC inverter• Battery• Permanent magnet AC motor
Battery
Inverter
Motor
Drive wheels
Generator
Engine
Power split device
Power circuit
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Kinetic Energy Recovery Systems
►Kinetic Energy Recovery Systems (KERS) are currently in different motor sport applications and moving towards road vehicles.
6
MotorGenerator
KERS Control Unit
Boost Request(energy to be released)
Driver
Breaking System(energy to be recovered)
Energy Recovery
Energy Release
Energy Storage System
DC
/DC
Battery
Flywheel
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Problem Statements
►Complex distributed system• Need for synchronization of multiple controllers including the transmission controller• High bandwidth communication needed
►System costs• Multiple controllers and sensors• Size of power units and el. machines dictate the system cost
►Power managements and motor control• Precise, fast and deterministic control timing• CPU high bandwidth is emphasized more than memory• Need optimized and flexible PWM output control for 3-phase motor control linked with fast
and effective analogue acquisition• DC/DC converter often needed for control of voltage conversion
►Functional safety• El. drive must guarantee torque production within specified limits• Fail silent architecture is required with “limp mode” for high system availability
7
TM
MCU System Impacts
8
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
MCU’s Control Energy Flow
►Main task is to control energy flow in the system:
• Inverter control• DC/DC control• Monitor eMotor/generator• Monitor ESS
►Communication between power conversion units is part of the control loop
►High-speed communication (such as FlexRay™) improves HEV system by:
• Better stability of the energy flow control
• Smaller temporary energy storages (capacitors/inductors) needed
9
ΔPeMotor ΔPCU ΔPESS
ΔPeMotor ΔPCU ΔPESS
Energy Recovery
Energy Release
Drive-train
Battery
Bat
tery
Driv
e-tra
in
ΔPeMotor ΔPESS
Drive-train
MotorGenerator
Control Unit
Energy Recovery
Energy Release
Energy Storage System
DC
/DC
ΔPCU
communication
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
MCU Based Digital Control System #1
►Main MCU peripherals are key drivers of the overall HEV system performance
►MCU is part of the control loop and provides in fact signal processing functionality. Data throughput defines control systemperformance such as response time, stability of the control loop, etc. Note: it is easy to change control technique/strategy/parameters since control is done on “soft”(ware) side.
10
MCU
Filte
r
Fast A/D
CPU
PWM Power Module Application
HIGH DATA THROUGHPUT REQUIRED
Control Loop
Communi-cation Port
TimerFilte
r
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
MCU Based Digital Control System #2
►Modified Harvard architecture increases architecture data throughput • CPU can read an instruction and perform a data memory access at the same time• HEV applications benefit from signal/control processing capabilities:
Simplification and cost reduction of existing sensors More sensors can be used within the same budgetMore information gained from sensorsMore intelligent application => increased safety, reduced fuel/energy consumption, emissions
11
MCU
Filte
r
Fast A/D
CPU
PWM
Communication Port
TimerFilte
r Data Memory
Instruction Memory
ALU
Control
Data Bus
Instruction Bus
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
MCU Based Digital Control System #3
►High performance CPU with advanced peripherals permits execution of advanced algorithms such as FOC, sensorless FOC and state observers
• Field Oriented Control (FOC) – independent torque and mag. flux controlThe current control performs equally well at low and high speeds. (PI controllers operating in the d-q reference frame of the rotor) is isolated from the sinusoidal variation of motor currents and voltages and therefore. Iq is made to equal the Torque Command, while Id is equal to zero which allows motors, when operating below base speed, to produce the rated torque at any speed. When Id is not equal to zero then the motor is in Field Weakening, operating above the base speed, where the maximum torque is reduced with increase speed.
• State variable observers (used in sensorless drives) addresses redundancy required by functional safety at SW cost
12
Inner Loop (faster) ~100Inner Loop (faster) ~100μμss
Outer Loop (slower) ~ 1Outer Loop (slower) ~ 1--5ms5ms
M
Motorola
Dave’sControlCenter
Supply
Position/speedsensor
Ib
IcMCU Power
Stage
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 13
MCU Based Digital Control System #4
Observer Based Control► Observers are simply real time
models of systems that are fed the same inputs as those provided to the real system (either commanded or measured)
► As a result, they estimate the real time response of the system to the inputs. A controller can be added to the real time model and used to force the observer model to track the measured states (Luenberger, Gopinath)
► Open loop Observer is formed on estimated model
► Closed Loop Observer K0 controller minimizes deviation of measured and estimated states
► Observers are key for plausibility check of the application behavior
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 14
MCU Based Digital Control System #5
List of needed matrix calculations
[ ] [ ][ ] [ ][ ] [ ][ ] [ ][ ] [ ][ ] [ ][ ] [ ][ ] [ ][ ] [ ][ ] [ ][ ] ××
××⋅×××⋅×××⋅×××⋅×××⋅×××−×××−×××+×××+×××+×
− 122
)'125(25555)'25(11555)'50(15225)'10(21225)'20(12225
1555511212155diag552151512222
1K
K
K
K
K
K
K
K
K
K
K
sMACsMACsMACsMACsMAC
Addition:
Subtraction:
Multiplication:
Inversion:
Matrix calculation scheme
[ ] [ ] [ ] [ ][ ] [ ][ ] [ ][ ] [ ][ ][ ] [ ][ ] [ ][ ][ ][ ] [ ] [ ]
[ ] [ ] [ ][ ] [ ]
$
$
x
P
x
P
K
k k
k k
k k
k k
k
= × + × × − × = ×
= × − × × = ×
= × × + × × = ×
= × × × + × = ×
= × × + × = ×
+
+
−
5 1 5 2 2 1 2 1 5 1
5 5 5 2 2 5 5 5
5 5 5 1 5 2 2 1 5 1
5 5 5 5 5 5 5 5 5 5
5 2 2 2 2 2 5 2
1
1
1
diag
Matrix inversion contains 1x division
Extend Kalman Filter based Observer► Observers are simply real time
365 MAC’s
TM
Power Conversion Units
15
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Benefits for DC/DC Converter and Inverter #1
► Advanced multi-channel high-resolution PWM peripheral permits: • Safe operation of the complementary power switches (including fault states)• To split the DC/DC converter and/or inverter into several phases
To reduce battery current ripples, DC-link ripples and el. motor torque ripples(e.g., 10-phase 100kHz DC/DC converter is equivalent to 1MHz single-phase converter)To prevent difficult paralleling of the power devices
• To use high-frequency high-efficiency switching devices• To achieve high density (10 kW/l) designs by
Reduced size of the energy storage components (inductors and capacitors)Improved packaging (it is easier to handle number of small components then one large one)
• To reduce material cost► Advanced ADC permits PWM-synchronous analogue acquisition of fast feedback
signals thus avoiding switching noise
16
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 17
Benefits for DC/DC Converter and Inverter #2
► High-resolution PWM peripheral:• Resolution, count (word) length:
PWM resolution is limited by device clock to PWM period ratio In another words, given the PWM/control period the device clock determines the max. range valueExamples:
20kHz period => Max. range 6000 LSB’s @ 120 MHz clock => 12.6 bit range100kHz period => Max. range 1200 LSB’s @ 120 MHz clock => 10.2 bit rangeResolution in both examples is 1 LSB => 8.33 nsecNote the minimum/maximum PWM duty cycle is limited by du/dt capabilities of the device I/O drive-stage. However, such limitation odes not affect 0% or 100% operation.
PWM period
High-resolution clock
Ran
geM
in. -
Max
.
Device Counter/Timer
Min./Max. PWM Duty Cycle
Low-resolution clockOutput at real device pin
due to limited du/dt
PWM
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 18
Benefits for DC/DC Converter and Inverter #3
► HEV application benefits from smooth low-speed operation• Torque control requires low-voltage at low-speed
<10% of nominal voltage needs to be generated• High-resolution PWM allows to generate low-voltage with required smooth torque control
el. motor speed
Base speed
Stator back-EMFMaximal voltage
0 3-Phase Power Stage
PMSM
Udc≈ k
High-resolution PWM
Low-resolution PWM
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 19
Benefits for DC/DC Converter and Inverter #4
► HEV application benefits from high frequency operation• DC/DC conversion can be done using higher PWM frequency • Hi-frequency PWM is possible without compromising the resolution• This leads to smaller, higher power density designs with less material use => lower system cost
High-resolution PWM
Low-resolution PWM
TM
Motor / Generator
20
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Asynchronous vs. Synchronous
►3-phase winding on the stator Distributed or concentrated
►Assumed sinusoidal flux distribution in air gap►Different rotor construction & consequences
• ACIMSquirrel cage (rugged, reliable, economical)No brushes, no PMLow maintenance cost
• Synchronous Rotor with permanent magnetHigh efficiency (no rotor loses)
►Synchronous motor rotates at the same frequency as the revolving magnetic field
►Asynchronous means that the mechanical speed of the rotor is generally different from the speed of the revolving magnetic field
21
ω
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
MCU Performance Impact to Motor/Generator
►High Resolution PWM (Pulse Width Modulator) Peripheral is key to design powerful electric motors at reduced cost:
• Motor/Generator to be small and powerful (not to carry unnecessary mass/space). shall be designed to work at high electric frequency (~1 kHz – high number of poles).
• Generation of high electric frequency 3-phase system requires high resolution PWM, both in time and amplitude
22
CuCue AABP σω δδπ ⋅⋅⋅⋅⋅≈Σ
1
Sine-wave generation
Low-resolution PWM High-resolution PWM
Air gap size × Sum of windings wire’s cross section
TM
Functional Safety
23
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 24
Safety Systems versus Functional Safety
Safety Systems
systems to protect against danger
outside the system
Functional Safety
the art to minimizedanger caused by a
(perhaps faulty) system
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Errors in the Electronic System
►How could the electronics have failed? And why?• Hardware errors vs. software errors• Permanent vs. transient error
A permanent error continues to exist until the system is repairedA transient error only occurs for a (short) time
– Border case: Error only ‘repaired’ by reset or power cyclingAn intermittent error is a transient error which re-occurs with a relatively high rate
• Random vs. systematic errorA random error is an error that occurs unpredictably (following a probability distribution)A systematic error is an error that occurs deterministically in certain circumstances (in all/many instances of the component)
►Classification as cross-product of three criteria
25
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 26
The Fault-Error-Failure Chain
Failure
Error
Fault
error detectionlatency
fault duration
faultdormacy
faultoccurence
faultactivation
errordetection
erroractivation
error latency
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 27
Environment
Fault Propagation in Systems
System
SubSystem A SubSystem B
SubSystem C
SubSystem A1 SubSys A2
SubSys A2a
SubSys A2b
SubSystem A3
A1a A1b A1c
B1 B2 B3 B4
Undetectedfault
Undetectedfault
propagation
Undetected external fault
induced
Fault affectingenvironment
Undetected external fault
causingfaults in the
systemthat affect
the environment
Development of a common cause fault
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 28
Possible System Reactions on an Error
► fail-dangerous: Possibly causes a hazard in the case of a failure► fail-safe: Returns to or stays in a safe state in the case of a failure
• the number of simultaneous faults is normally restricted to 1
► fail-operational: Continues to work correctly in the case of a failure• Possibly in a degraded mode only
► fail-silent: Will not disturb anyone in the case of a failure• This includes not providing wrong results
► fail-stop: Completely stops itself in the case of a failure• Typically needs a reset to get out of this mode again
► fail-indicate: Indicates to its environment that it has failed• But might continue to provide wrong results, hog resources, ….
► fail-inconsistent: Provided results will be noticeably inconsistent in the case of a failure
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Foreshadowing: Different Handling of Errors
►Knowing the error type is important as it influences how errors can be detected and handled
• Random errorsGoal: Reduce probability of occurrence (of effects) below a certain valueRisk can be estimated
• Systematic errorsGoal: Reduce probability of introduction into componentRisk caused by them is typically unknown
• Permanent errorsFunctionality stays destroyedCan be found by self tests
• Transient errorsFunctionality might recoverHappen more often; sometimes can be ignored
– e.g., if short and system safety time > 2*calculation cycle timeCan be found by time diversity
29
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Functional Safety Measures
►Self test measures• Ensure that the device/unit is free from dormant faults• Core self-test• Device self-test
►Error detection measures• Stop errors from propagating beyond component boundary
Error correction (compensation)Shut down (fail-silence)
• Hardware plausibility based– Illegal address/op-code detection, supervisor and user modes, memory error detection, ECC,
clock monitors, voltage supervision, watchdogs,
• Hardware redundancy based– Redundant peripherals, dual-core
►Development process measures• Avoid systematic failures• Follow process requirements defined by industry standards
30
MCU
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Safety Standards
►Two relevant safety standards• IEC 61508 (in revision)
Generic standard for functional safety of electronic systemsSpecialized versions for individual industries
• ISO 26262 (in preparation)‘Derivate’ of IEC 61508 for automotive applicationsAlready in used although not complete
►Goal• Prevent unacceptable risk due to failures of equipment
►Approach• Reduction of Systematic faults
Human-introduced ‘bugs’Constraints on development process
• Reduction of Random faultsFailures due to aging, interference, …Quantitative requirements via Safety metrics
31
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 32
IEC 61508 SIL versus ISO 26262 ASIL (approx. view)
SIL 1
SIL 2
SIL 3
SIL 4
ASIL A
ASIL B
ASIL C
ASIL D
Safety Integrity Level
IEC61508[today]
Ranking by assessing the probability of a dangerous
failure per hour
Automotive SIL
ISO26262[future]
Ranking by assessing severity of injuries, exposure to hazardous situations and the controllability of the driving situation
low
high
► Direct comparison not possible► Assessment of recommended and mandatory Hardware/software measures and
practices
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 33
Quantitative Requirements of IEC61508 versus ISO26262
►IEC 61508• 4 Safety Integrity Levels (SIL)• 2 key metrics
Probability of dangerous failure per hour (PFH)Safe Failure Fraction (SFF)
• Hardware redundancy in formulas (HFT)
SIL 1 SIL 2 SIL 3PFH [1/h] <10-5 <10-6 <10-7
SFF (HFT=0)
>=60% >=90% >=99%
SFF (HFT=1)
- >=60% >=90%
Note: Table adopted for typical automotive application
►ISO 26262• 4 Automotive SILs (ASIL)• 3 key metrics
Probability of violation of safety goals (PVSG)Single Point Fault MetricLatent Fault Metric
• Hardware redundancy in structural modeling
ASIL B ASIL C ASIL DPVSG [1/h]
<10-7
(recom.)<10-7 <10-8
SPFM >90% >97% >99%
LFM >60% >80% >90%
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 34
Intention of the Requirements
►3 intended effects• Reduce probability of a dangerous failure• Demonstrate effectiveness of measures against
immediately dangerous faults• Demonstrate effectiveness of measures against
latent faults which could accumulate
►Different measures against single point and latent faults• Single point faults
Detect within system safety timeExercised by system/application itself
• Latent FaultsDetect within hours/daysExercised by test routines
PFH
SPFM , SFF
LFM , SFF
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 35
MCU Architectural Breakdown
Core
MMU
Cache
BUS
RAM Flash
MPU
Peripheral Bridge DMA
Sensor & Actuator Ctrl CommunicationResets &Interrupts
Power
Config
Clock & Timing
Failurereporting
Debug
ComputationalSubsystem
Peripherals
Auxiliaries
1
2
3
4
All subsystems involved or influencing a typical application⇒ All require safety measures
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 36
Philosophies for Functional Safety – Examples
Core+
Periphery Memory
Aux
Safety related SW
SW self tests
Online Software Self Tests Single Core with Time Redundancy
Core+
Periphery Memory
Aux
Safety related SW
Two Asymmetric Cores
SR SW Compare
Memory
Core+
Periphery Memory
Aux
Safety related SW SW
SmallCore
Two non-locked Cores + SW Comparison
Core2+
Periphery Memory
Aux
Safety related SW SW 2
Core1+
Safety related SWSW 1
Compare
Two Cores in Lockstep
Core2+
Periphery Memory
Aux 3
SW
Core1+
Aux 1 Aux 2
Compare
Aux 3Supervisors
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 37
Comparison of Architectures
HW Architectures
Single Core
Asymmetric Cores
Dual Core
Dual Core Lockstep SW Effort Detection of
SW Errors
Single SW Instance - - - ASIL D - -
Replicated SW Instances
ASIL A(Time
redundancy)
Not common ASIL D Makes little
sense + -
SW
Approach
Diverse SW Instances
ASIL A-B(Time
redundancy)ASIL C-D ASIL D
ASIL D(Time
redundancy)++ +
Startup Self-Test
Makes little sense
Required for sufficient LFM
Required for sufficient LFM
Required for sufficient LFM
Self-Test Online
Self-Test ASIL A Not common
Not common
Not common
HW Effort - + + ++
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 38
Last but not Least … Software Safety
►Hardware Development Tools• Inject a systematic fault into the HW
e.g., Wrong synthesis, too small/close/slow/…. signals or gates, ….
►Software Development Tools• Inject a systematic fault into the SW
Compiler errors, Configuration mixups, ….
►Hardware Control and Driver Software• Accessing the hardware in a wrong way
Timing, Error handling, ….
►Application Software• Not realizing the application function in all cases
Various bugs possible
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 39
Software Development for Certification
► Both standards recommend process, information to exchange, and measures to apply• IEC 61508-3• ISO 26262-6 (draft)
► Process• V-Model
► Information to exchange• Plan/Specify – Execute – Report
► Measures to apply• ISO often more concrete than IEC; IEC more comprehensive
ISO has measures embedded in subsections (vs. tables at end in IEC)– leads to repetition
• IEC explains most measures in part 7• Mainly good software engineering practices required, e.g.,
Structured, hierarchical architecture & design– unambiguous
Defensive programmingLimited pointer usageVarious testing techniques
• Tables can be used as checklists (and expanded upon)
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 40
Software Development for Certification
► Both standards recommend process, information to exchange, and measures to apply• IEC 61508-3• ISO 26262-6 (draft)
► Process• V-Model
► Information to exchange• Plan/Specify – Execute – Report
► Measures to apply• ISO often more concrete than IEC; IEC more comprehensive
ISO has measures embedded in subsections (vs. tables at end in IEC)– leads to repetition
• IEC explains most measures in part 7• Mainly good software engineering practices required, e.g.,
Structured, hierarchical architecture & design– unambiguous
Defensive programmingLimited pointer usageVarious testing techniques
• Tables can be used as checklists (and expanded upon)
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Functional Safety
►Hardware and Software techniques must be considered jointly whenassessing the (A)SIL of a safety system
►Good functional safety MCU architecture shall• Fully support required (A)SIL measures/techniques with no or minimum overhead• Minimize development effort (software + hardware) at competitive development cost• Minimize performance impact
►MCU software shall be based on the following techniques:• Fault detection and diagnosis• Error detecting and correcting codes• Diverse programming• Backward/Forward/ Re-try fault recovery• Graceful degradation• Intelligent fault correction• Dynamic reconfiguration• …
41
TM
Freescale Advanced Solutions
42
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 43
1MB – MPC5643LCore• Up to 120 MHz Dual e200 zen4 core built on Power
Architecture technology, 240 DMIPS• 4K 2-way / 4-way I-cache• FPU• Safety enhanced Cores + FPU + VLE + MMU• Dual Parallel or Lock Step configuration + HW/SW monitoring
Memory• Up to 1 MByte RWW Flash with ECC• Up to 128 KByte SRAM with ECC• EE emulation• Dual crossbar with MPUs
I/O• 2 x FlexCAN (32 message buffers each)• 1 x FlexRay™ (64 msg. buffers)• 2 x LINFlex• 3 x DSPI • 1 x External clock output • 2 x FlexPWM (2 x 12 channels)• 3 x eTimer modules (3 x 6 channels)• Dual ADC (16 channels each, 12bit, 650ns), 1 S/H per ADC• 1 x Cross-triggering unit for motor control
System• 16 Channels eDMA• Autonomous Fault Collection and Control Unit• CRC computing unit• Software watchdog timer (inc. window mode, flow monitoring)• 2 x Junction temperature sensor • Nexus debug interface (up to N3)• FM-PLL + FlexRay PLL • 3.3 V Single supply with external and internal ballast transistor• 3.3 V I/Os (ADC 5 V capable)• 144 LQFP / 257 MAPBGA• Tj = 150°C
Cross Bar Switch
I/OBridge
Memory Protection UnitCross Bar Switch
Memory Protection Unit
FlexRay
RC
RC RC
1MFLASH(ECC)
128KSRAM(ECC)
RC
I/OBridge
PMU
SWT
MCM
STM
INTC
eDMA CACHE
e200Core
MMU
VLE
CACHE
FPU Nexus
JTAG
Debug PMU
SWT
MCM
STM
INTC
eDMACACHE
e200Core
MMU
VLE
CACHE
FPU
Com
mun
icat
ions
I/O S
yste
m
2 x LIN
Flex
3 x DSPI
2 xA
DC
2 FlexC
AN
3 x eTim
er
FCC
U
2 xFlexP
WM
CTU
TSENS
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 4444
3x Timer Module:• 8.3 ns edge resolution• Six Ch IC/OC• Double buffered registers for
detecting two edges in a row• eDMA supported• Integrated quad decoder support
MCU
CTU
eTimer(Pos Counter)
PWM Reload
Timer/ Pos. decoder compare
External Signal
External Trigger
Trig
ger G
ener
ator
eTimer
flexPWM
Sch
edul
er
ADC Cmd
ADC Trig & Ackw
RealPWM’s
PWM’s
PWM Triggers
Real PWM’sADC Inputs
AD
C 1
SHAR
ED
AD
C 2
MPC5643L – Electric Motor Control Peripherals
2x FlexPWM• 8.3 ns edge resolution• Optimized for 3-ph motor control• One „extra“ pair of PWM integrated• Includes dead time insertion, fault channels,
center/edge alignment, Distortion correction, …
• Register (configuration) protections• Double buffered registers• Safe reload mechanism• eDMA supported
2x ADC• Up to 22 channels, with 4 shared. • 12-bit• 650 nsec conversion time• Limit checking & zero crossing detect
1x Cross Triggering Unit• Allows mcTIM, PWM, ATD
to be synchronized• Automatic ADC & eTimer acquisitions • No CPU intervention during the
control cycle• Over-run faults detection• Safe reload mechanism
PWM0 Ch0PWM0 Ch1
PWM1 Ch0PWM1 Ch1
PWM2 Ch0PWM2 Ch1
PWM3 Ch0PWM3 Ch1
Con
trol
M
M
DC/DC
8
2
6
9 4 9
12bit
S&HMUX
I/F12bit
S&HMUX
I/F
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 4545
► Main Features► 4 Submodules, each with complementary PWM generation, Isense
IC/OC and fault input
► 16 bits of resolution for center, edge aligned, and asymmetricalPWMs
► PWM outputs can operate as complimentary pairs or independent channels
► Independent control of both edges of each PWM output
► Independently programmable PWM output polarity
► Separate dead time for rising and falling edges
► Each complementary pair can operate with its own PWM frequency and deadtime values
► All outputs can be programmed to change simultaneously via a "Force Out" event
► Double buffered PWM registers• Integral reload rates from 1 to 16• Half cycle reload capability
► Safety► Write protection for critical registers
► Fault inputs can be assigned to control multiple PWM outputs
► Programmable filters for fault inputs
PWM0 Ch0
Con
trol
PWM0 Ch1
PWM1 Ch0
PWM1 Ch1
PWM2 Ch0
PWM2 Ch1
PWM3 Ch0
PWM3 Ch1
Faults
Internal triggers
Complementary Pairs PWM Modes
Independent ChannelPWM Modes
auX
auX
auX
auX
• Permanent magnet synchronous motor (PMSM, PMAC) • Brushless DC motor (BLDC)• Brush DC motor (BDC)• AC induction motor (ACIM) • Switched reluctance motor (SRM) • Variable reluctance motor (VRM) • Stepper motors• DC/DC converters
CMP1CMP2Independent
Edge Control
Motor Control PWM Peripheral Module
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 4646
Independent Edge Control – Edge Aligned PWM
PWM output
ValONValOFF
INIT
Val00
-4
34
-3
Case A Case B Case C Case B Case A0% 100% 75% 100% 0%
• Case A• Duty cycle – 0%
General– x% = 0%– ValON <= INIT– ValOFF <= INIT
Example– MOD = 8– x% = 0– INIT = -4– Val0 = INIT + MOD – 1 = 3– ValON = -4– ValOFF = INIT + MOD * x% = -4
• Case B• Duty cycle – 100%
General– x% = 100%– ValON <= INIT– ValOFF >= INIT + MOD > Val0
Example– MOD = 8– x% = 100% – INIT = -4– Val0 = INIT + MOD – 1 = 3– ValON = -4– ValOFF = INIT + MOD * x%
= -4 + 8 * 100% = 4
• Case C• Duty cycle – 75%
General– x% = 75%– ValON <= INIT– ValOFF = INIT + MOD * x%
Example– MOD = 8– x% = 75% – INIT = -4– Val0 = INIT + MOD – 1 = 3– ValON = -4– ValOFF = INIT + MOD * x%
= -4 + 8 * 75% = 2
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 4747
Independent Edge Control – Centre Aligned PWM
PWM output
ValONValOFF
INIT
Val00
-4
34
-3
Case A Case B Case C Case B Case A0% 100% 75% 100% 0%
• Case A• Duty cycle – 0%
General– x% = 0%– ValON = 0– ValOFF = 0
Example– MOD = 8– x% = 0– INIT = -4– Val0 = INIT + MOD – 1 = -(INIT) -1 = 3– ValON = -(MOD/2 * x%) = 0– ValOFF = -(ValON) = 0
• Case B• Duty cycle – 100%
General– x% = 100%– ValON <= INIT– ValOFF >= -(ValON) = -(INIT) > Val0
Example– MOD = 8– x% = 100% – INIT = -4– Val0 = INIT + MOD – 1 = -(INIT) -1 = 3– ValON = -(MOD/2 * x%) = -4– ValOFF = -(ValON) = -(-4) = 4
• Case C• Duty cycle – 75%
General– x% = 75%– ValON = -(MOD/2 * x%) – ValOFF = -(ValON)
Example– MOD = 8– x% = 75% – INIT = -4– Val0 = INIT + MOD – 1 = -(INIT) -1 = 3– ValON = -(MOD/2 * x%) = -3– ValOFF = -(ValON) = -(-3) = 3
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 4848
Independent Edge Control – Quasi-Centre Aligned PWM (Full Resolution)
PWM output
0
-4
34
-3
Case A0%
Case B100%
Case A0%
Case B100%
Case C62.5%
ValONValOFF
INIT
Val0
• Case A• Duty cycle – 0%
General– x% = 0%– ValON = 0– ValOFF = 0
Example– MOD = 8– x% = 0– INIT = -4– Val0 = INIT + MOD – 1 = -(INIT) -1 = 3– TMP = MOD/2 * x% = 0– ValON = -round(TMP) = 0– ValOFF = truncate(TMP) = 0
• Case B• Duty cycle – 100%
General– x% =100%– ValON <= INIT– ValOFF >= -(ValON) = -(INIT) > Val0
Example– MOD = 8– x% = 100% – INIT = -4– Val0 = INIT + MOD – 1 = -(INIT) -1 = 3– TMP = MOD/2 * x% = 4– ValON = -round(TMP) = -4– ValOFF = truncate(TMP) = 4
• Case C• Duty cycle – <0%,100%>
General– x% = <0%,100%>– TMP = MOD/2 * x% – ValON = -round(TMP– ValOFF = truncate(TMP)
Example– MOD = 8– x% = 62.5% – INIT = -4– Val0 = INIT + MOD – 1 = -(INIT) -1 = 3– TMP = MOD/2 * x% = 2.5– ValON = -round(TMP) = -3– ValOFF = truncate(TMP) = 2
In comparison with standard Centre-aligned PWM, this method improves resolution by 2x. It can increase ON time just by single count (min. two for C-A PWM) and keeps the ON pulse at the centre within ±½ count (±4.15 ns @ 120 MHz).
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 4949
Independent Edge Control – Other PWM Paterns Example
►3-ph PWMs can be divided into:
• Standard – center aligned
• Two active vectors – left aligned
• Three active vectors – sequential
• Two active vectors – centered
• Three active vectors – center aligned (double switching)
60° - 120° 240° - 300°
120° - 180°60° - 120°
0° - 60° 60° - 120°
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Sinusoidal Modulation – Limited in Amplitude
►In sinusoidal modulation the amplitude is limited to half of the DC-bus voltage
►The phase to phase voltage is then lower then the DC-bus voltage (although such voltage can be generated between the terminals)
50
UD
C-B
US
Uph
ase-
phas
e BC
A
PWM3PWM1
PWM4PWM2
PWM5
PWM6
Can such a modulation technique be found that wouldgenerate full phase-to-phase voltage?
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Full Phase-to-Phase Voltage Generation
►Full phase-to-phase voltage can be generated by continuously shifting the 3-phase voltage system
►The amplitude of the first harmonic can be then increased by 15.5%
51
Uph
ase-
phas
e
BC
A
PWM1
PWM4PWM2
PWM3 PWM5
PWM6 Uph
ase-
phas
e BC
A
15%
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
How to Increase Modulation Index
►Modulation index is increased by adding the “shifting” voltage u0 to first harmonic
►“Shifting” voltage u0 must be the same for all three phases, thus it can only contain 3r harmonics!
52
B C
A
15%
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 5353
► Main Features
► 2 Independent units• 4 channels shared on ADC1 and ADC2
► 4 shared signals for motor control acquisitions• 3 for phase currents• 1 for other acquisitions
► 650 ns conversion time128 ns sampling time
► 12-bit resolution
► Single sample and hold per ADC• Dual sample through ADC cross triggering
► Separate sampling and conversionclock pre-scalers
► Analog watchdogs allow continuous hardware monitoring
Motor Control ADC Peripheral ModuleADC Unit
►ADC_INTERRUPTS
ADC data registers
►D15►D14►.►.►.
►D1►D0
SUCCESSIVE APPROXIMATION A/D CONVERTER
SAMPLESAMPLE
& &
HOLDHOLD
12 bit12 bit
ConvertorConvertor
AIN0
AIN1
AIN15
..
..
..
ANALOG MUX
►ADC_CONTROLTrigger Event for
conversion
Trigger event for injected conversion
END OF CONVERSION
END OF INJECTION
THRESHOLD VIOLATION
INTERRUPTS
Results FIFOs
►Analogwatchdog
SUCCESSIVE APPROXIMATION A/D CONVERTER
SAMPLESAMPLE
& &
HOLDHOLD
12 bit12 bit
ConvertorConvertor
AIN0
AIN1
AIN15
..
..
..
ANALOG MUX
9 4 9
12bit
S&HMUX
I/F12bit
S&HMUX
I/F
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 5454
Motor Control Cross Triggering Unit
► Main Features
► Two modes of operation:• Sequential mode• Triggered mode
► Schedule acquisition of the state variables (ADC, position counter, PWM duty cycle decoder) with respect to PWM cycle
► ADC commands stored in ADC lists
► Support for over-sampling
► Triggers activate an ADC list• ADC commands can be static• Triggers are changed according to space
vector location
► Trigger generation, ADC commands and ADC lists are double-buffered
► Manages both ADCs
► No real time involvement of CPU
► Compliant with ISO26262 for reduction of CPU interrupts
► DMA support
CTU
Trigger GeneratorSubunit
eTimer1
External signal
SchedulerSubunit
PWM triggersodd
Real PWM’s/IsenseX
Trigger0..7
eTimer2/ Pos. decoder
compare
PWM reload
2 x CLK
ADC Command Bus
External trigger
Presc.
Master Reload
eTimer1
eTimer2/ Pos. decoder compare
PWM triggerseven
Trigger
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 5555
ADC Commands► ADCs must be in CTU control mode► Commands List of 24 commands► Commands List registers are double-buffered► Single conversion mode or dual conversion mode► The result of each conversion, in both modes, can be
stored in one of the 4 FIFOs► The interrupt request bit is used as an interrupt request
to the CPU when ADC will complete the command► The commands in the list will allow to have control on:
• Channel A number: number of ADC channel to sample from ADC unit A (4 bits)
• Channel B number: number of ADC channel to sample from ADC unit B (4 bits)
• FIFO selection bits for the ADC unit A/B (2 bits)• Conversion Mode selection bit• First command bit (only for CTU internal use)• Interrupt request bit
► 1 trigger from CTU initiate execution of the ADC command list; such command list can contain conversion stream (multiple ADC acquisitions)
Conversions only triggered by CTU
ADCch0...chN...ch23
CTUChannel ConversionCommand
Result FIFOs
CPU/eDMA
Memory
eTimer,FlexPWM
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 56
Cross Triggering Unit Benefits
PWM Period
PWM topPWM Bottom
Phase Current
Sampled and Average Currents
A/D
Control action calculation
New PWM Parameters Calculation with Half-cycle Reload
►ADC sampling helps to filter the measured current – anti-aliasing►Noise free ADC sampling when the power switch is not acting
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 57
microcontroller
microcontroller
Delays Involved in ADC-PWM Synchronization
► Delays are chained and are caused by:• Dead time insertion• Opto-coupler propagation delay• IGBT Driver propagation delay• IGBT turn ON/OFF times• Sensor slew rate
Low-pass filter delay• ADC delays
i+
PWM1
50 A
+-
GND
+5V
LPF ADC
Driv
erOverall delay: ~0.4 ÷ 6 us
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 58
Internal counter
Desired PWM
Cross Triggering Unit – Synchronized (Over)Sampling
Overall delay: ~0.4 ÷ 6 us
ADC trigger output event
ADC clock sync. ADC MUX selection S&H
ADC sample
Trigger advancement to compensate ADC delays
ADC delays
Low pass filter delay + Topto: ~1usReal feedback signal
at ADC pin
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 59
Control Signals Scheme – PWM_AD_MCU
abc
Desired PWM’s
Phase Currents
DC-Link Currenta -c a -c a -c
Sin/Cos
DC-link Voltage
ADC AcquisitionIC of Real PWM
Control Loop Calculation
PWM Commands ADC Triggers Setting
Real PWM’s
6x IC’s
on-the-fly reference calibration
- ADC sample- PWM switching noise
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 6060
Microcontroller
ADC
TIMER
PWM
Cross Triggering Unit
Resolver Physical LayerResolver Physical LayerUcos
Usin
Resolver θ
GNDUref
Vdc
3-Phase Low Voltage Power Stage
PWM Isa Isc
U_Dc bus
Isb
U_D
c bu
s
Motor
Differential Amplifier + FilterDifferential Amplifier + Filter
3.3V
0V
3.3V
0V
Resolver Ref. DriverResolver Ref. Driver
Advanced Peripherals Enable On-chip Resolver-to-Digital Conversion
IRef 20-100 mA
LP
Filte
r
Tracking Observer Algorithm - SW
Tracking Observercomputation
co-sine samplesine sample
position speed # revolutions
Synchronization
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 6161
Resolvers
► Rotor is put directly on the drive’s shaft► Stator is fixed on drive’s shield► Simple assembly and maintenance► No bearings — “unlimited” durability► Resist well against distortion, vibration,
deviation of operating temperature and dust► Worldwide consumption millions of pieces at
present time► Widely used in precious positioning
applications► The number of generated sine and cosine
cycles per one mechanical revolution depends on the number of resolver pole-pairs (usually 1-3 cycles)
Sensor Principle
Auxiliary transformer Rotor StatorAuxiliary
transformer Rotor StatorAuxiliary
transformer Rotor StatorAuxiliary
transformer Rotor Stator
Uref
Usin
Rotor shaft
θ
Ucos
ω
Uref
Usin
Rotor shaft
θ
Ucos
ω
0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009 0.01
Sinusoidal Voltage
0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009 0.01
Co-sinusoidal Voltage
0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009 0.01
0.5
-1-0.5
0
1
-1-0.5
00.5
1
-1-0.5
00.5
1 Reference Voltage
Sensor Components
Resolver Parameters:Electrical Error – +/-10’, Transformation Ratio – 0.5, Phase Shift – +/-10°Input Voltage – 4-30V, Input Current – 20-100mA, Input Frequency – 400Hz-10kHz
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Angle Tracking Observer
►Method Basics:
►Features:• Robust method in term of noise • High accuracy of the angle extraction, speed estimation for free as side effect• Can deal with non-sinusoidal signals/envelops• Can be implemented fully digitally
62
Pos. Error ComparatorPos. Error
Comparator RegulatorRegulator
Angle TrackingAngle Trackingω
θω
e(θ)Envelope ExtractorEnvelope Extractor
LPFilterLP
Filter
ωest
θest
SineCosine
Generator
SineCosine
Generator
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 6363
Accuracy
N = 13-bitError = ± 1LSB
±π = ± N-1 bit
N = 10-bitError = ± 1LSB
Experimental Results
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Motor Control eTimer Peripheral Module
► Main Features► Six 16-bit general purpose up/down
timer/counter per module► Powerful multiplexer between external pins
and internal signals for external triggers► Individual channel capability:
• Input capture trigger• Output compare• Many counting modes (gating; triggered; one-shot)• Separate prescaler for each counter• Selectable clock source• Rotation direction flag (Quad decoder mode)
64
► Dual action capability per channel• PWM measurement 0% to 100%
► Quadrature decoder• rotor position• rotor zero speed detection (position watchdog)
► ADC trigger can also trigger input capture for rotor position measurement (ex: sin/cos sensor)
► Cascade able for higher precision (32 bits)
Sec.Input
PRIMARY
SECONDARY
PRESCALER
MUX
STATUS & CONTROL
DMA IF
COUNTER
TMRLOAD TMRHOLD
Edge Detect.
CAPTURE CAPTURE
CAP Buf.1 CAP Buf.1
TMRCMP1 TMRCMP2
CMPLD1 CMPLD2
COMP. COMP.
MUX OFLAG
OutputPrim.Input
CONTROL
OUTPUT
DATA BUS
Peripheral Clock
WD Count
UP/DNOutput Disable
OTHER CTNTRS
eTimer Channel
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 6565
IC 1
IC1IC2
Counter
forward forwardjitter jitterbackward
PRESCALER 16-BIT
Trigger/ClockController
Input Capture
ARR16 bit Counter
Encoder Interface
IC 2
Output Trigger
Output Compare
Encoder Index
eTimer – Encoder Interface Mode
► The counter is clocked by each valid transition on IC 1 or IC 2 by incremental encoder
► Depending on the sequence the counter counts, automatically, up or down
► The output of encoder interface can be connected to encoder index to reset the counter on zero position detection
► The timer can provide information on encoded position► To obtain dynamic information (speed, acceleration,
deceleration) by measuring the periods between two encoder events using a second timer
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 6666
Encoder Interface Mode — Safety
► Position WATCHDOG Timer/Counter
► Two successive counts indicate proper operation and will reset the timer.
► The timeout value is programmable. When a timeout occurs, an interrupt to the processor can be generated.
► This timer is separate from the watchdog timer in the COP module.
PHASE A
PHASE B
+/-1
PositionCounter
Incr. Encoder
What happens when PHASE A is cut off ?
Normal Operation
Operation at phase cut off
Pos. WatchdogInt. Request
Watchdog timeout
ISR
+/-1 counts of the Position Counter do not reset the Watchdog timer!
The Watchdog can detect the encoder signal line cut off!
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 67
Software - Motor Control Library – Key Features
►All functions ANSI-C MISRA compatible for easy porting to other target platforms
►Independent of target platform peripherals►Theory and performance results summarized in extensive
documentation►Delivery as object file enabling easy way of integration►Bit accurate Matlab/Simulink models included►Reference models for Matlab/Simulink, and test vectors available on
demand
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 68
Software - Motor Control Library Structure
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 69
Software - Motor Control Library – Application Example
MPC56xx
FreeMaster
-
Forward ClarkTransformation
a,b,c >alpha,beta
Current Sensing
Processing
-
Forward ParkTransformationalpha,beta>d,q
SpeedController
Current qPI
Controller
PWMModulation
-
Inverse ParkTransformationd,q >alpha,beta
Current dPI
Controller
-DC busripple
compensation
Is_a
_com
p
Us_alpha
Us_beta
Is_b
_com
pIs
_c_c
omp
Is_beta
Is_alpha
Is_q
Is_d
Us_q
Us_d
Is_q_Req
Us_alpha_comp
Us_beta_comp
Spe
ed_R
eq
Is_aIs_bIs_c
U_d
cb
Duty cycle aDuty cycle bDuty cycle c
Angle Tracking Observer
theta_actual_elsin cos
Application ControlSector
Resolver HW
Sin
e
Cos
ine
Ref
Sin
eC
osin
e
START/STOP
12 V
dc
3-Phase Low Voltage Power Stage
PWM Isa Isc
U_Dc bus
Isb
U_D
c bu
s
6PMSM6PMSM
Load
Encoder
SoftwareSwitch
Resolver
Field Weakening Controller
SCI
Driver Driver
GPIOADCPWM eTimerGPIO
Driver Driver Driver Driver
Om
ega_
atua
l_m
ech
Fault Protection
Faults
Angle Tracking Observer
Pos
ition
cou
nt
CTU
Driver
MCLIB functions
TM
Freescale Functional Safety Solutions
70
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 71
Challenge - Systems Become Components
In the past strong separation of systems and components.
More recently, however, complete systems are being condensed to single components.
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Functional Safety Aspects for System-on-Chip
►It must be possible to test correct function of every safety feature• At least after reset — ideally during operation• Common technique: intentionally trigger specific error scenarios and check if the device
behaves as expected• Read-back of settings (registers) is important but not sufficient
►Configurable safety features• Make sure the default configuration is the most stringent one (highest level safety)• Make sure the configuration cannot be changed by a wild going unit• Consider a challenge-response protocol or other mechanisms that require “intelligent”
behavior of the unit before changing configurations that have a critical impact
►Graceful degradation• In case of a fault of the unit it should behave “gracefully” (manageable, detectable)• When designing safety features take into account that faults may affect their correct
operation as well – document measures to manage these cases (frequently on application level)
• Some circuitry can be designed in a self checking way, which requires some redundancy –however full duplication usually not necessary to detect faults
72
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 73
I/OBridge
Memory Protection UnitCross Bar Switch
Memory Protection Unit
RC RC
1MFLASH(ECC)
128KSRAM(ECC)
I/OBridge
PMU
SWT
MCM
STM
INTC
eDMA CACHE
PowerPC™e200
MMU
VLE
CACHE
FPU Nexus
JTAG
Debug PMU
SWT
MCM
STM
INTC
eDMACACHE
PowerPC™e200
MMU
VLE
CACHE
FPU
Com
mun
icat
ions
I/O S
yste
mM
CM
MC
M
2 x LIN
Flex
3 x DSPI
2 FlexC
AN
3 x eTim
er
FCC
U
2 xA
DC
2 xFlexP
WM
CTU
CR
C
TSENS
TSENS RC
Sphere of Replication
FlexRay
RC
MPC5643L - Ready for Functional Safety
Flash + Data Block•Provides ECC for both program Flash and Data Flash
Cross Bar Switch
Core built on Power Architecture Technology
• Replicated e200 core• Replicated eDMA• Redundant INTC,
crossbar and I/O bridge
Clock Monitor•Detect and mitigate clock disturbances Temp monitor
• Redundant temp monitor
FlexRay™2 ch @ 10 Mbps
ADC•Shared inputs•On Line Assisted Hardware BIST
eTimer Modules• Redundant operation• loop-back mode Fault Collection Unit
• detects when errors have occurred
• indicates error to external• brings device into safe state • independent of software
operation
Watchdog TimerRedundant operation
RAM• Provides ECC in HW• Higher safety than SW
signature at no speed constraint
CRC Module•Calculate Application signatures
Interrupt Controller• Redundant operation
Memory Management Unit• Memory HW access
control for Core, eDMA, FlexRay
Redundancy Checkers•Cycle-by-cycle comparison of the SoR
Power Management Unit• Separate Vreg and
redundant Vreg monitor
FlexPWM Module• Loop-back mode
KAL1 KAL2
Slide 73
KAL1 Need to remove PowerPC from the e200 block and put "e200 core"rm027c, 5/4/2010
KAL2 Need to remove PowerPC from the e200 block and put "e200 core"rm027c, 5/4/2010
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 74
MPC5643L Safety Concept – Turn-key Solution for SIL3 Certification
► MPC5643L safety concept has been defined with the target to meet IEC 61508 2nd ED WD safety standard to simplify system design, reduce development cost and minimize certification costs:
► Main Elements• Processing subsystem (Sphere of Replication):
No software requirements on start-up diagnostics (Logic BIST) No software requirement during application time
• SRAM Memory:No software requirement at start up (Memory BIST)
• Flash Memory:On-line test needed only to check ECC logicHardware assisted array integrity startup test
• Peripherals:Safety concept generic to application without specificities on the usage and control methodOn Line hardware assisted BIST for the ADCCRC Unit for Fault tolerant communication layer and Application data protection
• Centralized Fault Collection and Control UnitIndependent from the CPUConfigurable graded reaction to faults
• Minimum requirements on external circuitry (external watchdog, voltage monitoring) and software► Safety Application Guide detailing requirements on external circuitry and on software
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Comparison of Different Dual-core Modes for Selected Fault Examples
Mode
Dual-core w/o safety
Dual-core w/o safety + SW Rep
Dual-core w/o safety + SW Div
DPM DPM + SW Rep
DPM + SW Div
LSM LSM + SW Div
Adapted LSM
Adapted LSM + SW Div
FPU-Fault (Single channel fault)
INTC fault (stop fault)
Voltage too low (CCF)
CAN clock (safe fault)
Annoyance failure not caught Reaction highly SW dependent Shutdown Graceful degradation
SW fault
Modes possible with MPC5643L
Demo at: http://www.freescale.com/webapp/sps/site/training_information.jsp?code=WBNR_MPC564XL_SAFETY
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc. 76
Example of Cost Effective Functional Safety Architecture
MPC5643L
IntelligentWatchdog
CPU Replicated CPU
Actuator’sEnergyControl
(DC-link Main Switch)
Actuator(s)
(Power Stage)
Sensor(s)
ActuatorControl
(IGBT Drivers)
disable
disable
control values
energy
controlsignals
token_Atoken_B
input value
input value
Fail Silent System
Redundant Peripherals
TMFreescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLinkand VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.
Safety Function and Fail Safe State
►Safety Function: • Perform in specification or move to the Fail Safe State within the
following assumptions:Dedicated periodic and/or diagnostic tests are executed at boot-time
– E.g., Build in Self Test at bootPeriphery is used in an application specific manner
– E.g., Motor control, communication peripheralsExternal watchdog (via FCCU error pins)
►Fail Safe State: • The device fail safe state is either the micro-controller reset or the “Error
Out” signaling with the appropriate protocol.
77
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Freescale Functional Safety Application Guide
►Safety Application Guide• For safety certifications customers (not only)• Describes safety functions provided, how they work, what they can address/not
address
TM
Motor Control on Freescale Website
79
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Freescale Motor Control Web Sitewww.freescale.com/motorcontrol
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Freescale Reference DesignsFreescale > Reference Designs (under “support” tab)> Motor Control
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Freescale Reference DesignsFreescale > Reference Designs > Motor Control > DC Motors - Brushless DC Motor (BLDC)
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Summary
►Not surprisingly microcontroller is key element of the system and defining system overall performance
►High-performance CPU architecture• Improve control loop time• Provides hardware support for functional safety measures• Allows to implement complex (but effective) software safety measures
►Advanced peripherals help to reduce system cost• Reduced complexity of external circuitry• Lowered system size and mass• Easier packaging
►Today microcontrollers support and are integral part of functional safety solution
• High diagnostic coverage• Minimum impact to overall performance, cost and development effort
TM