C2000-sway022a
C2000-sway022a
generation of low-cost,
dual-axis servo drives
Brian Fortman
C2000™ Marketing
Texas Instruments
As factory automation continues its rapid adoption
of precision motion control in industrial machines,
the number of servo motors and servo drives used
in these applications is skyrocketing.
Some analysts have characterized the servo drive market as “unbounded” as the
applications expand. This is not surprising as previous manual processes become
automated: the mechanical power capability of today’s servo motors can be a practical
replacement for pneumatic and hydraulic-based actuation.
Motion control and servo drive advancements – With the release of the F28004x and F28002x
enabled by servo drive and servo motor hardware series of C2000™ microcontrollers (MCUs), Texas
enhancements such as the transition of inverter Instruments (TI) has enabled a new value point
switches away from insulated gate bipolar for dual-axis drives that also delivers very robust
transistors (IGBTs) toward higher-speed gallium motion-control performance. The value comes not
nitride (GaN) and higher-power silicon carbide (SiC) only from the achievable control performance and
technology – remain essential for competing in the ability to drive two motors concurrently, but also
global economy. The market dynamics also remain from the high degree of on-chip integration of other
extremely competitive. Suppliers seek advantages key electronic system functions.
for their servo drive lineups in system-level criteria
including control performance, connectivity, ease of
use and cost.
C2000™ MCUs enable the next generation of low-cost, dual-axis servo drives I 2 July 2020
F280049C Temperatures 125C Tj Q100
In this white paper, I will show the superset F28004x Integrated peripherals support
features that enable support for dual axes, with dual-axis drives
control technology that delivers unprecedented
The F28004x (TMS320F280049C) series is a
motion control performance and the opportunity
scaled down version of the popular F2837x
to further reduce the bill of materials by using both
(TMS320F28379D) series. TI carried forward the
new and legacy features integrated onto a real-time
accelerator and peripheral enhancements and
controller.
added a few additional features for AC drives and
servo applications, as shown in Figure 1.
Sensors
Current Integrated Pgm gain amps (7x)
loops 3x ADC DS Isolated
DS Isolated
C28 ADCs
ADCs
12-bit, 3.5 MSPS
DSP w/ 4x sinc filters
TMU Sinc filters PM
2x per motorMotor
feedback
PM
Motor
eQEP (ABZ) with OV/UV comparison
Position
Position
Line Sensor
Position manager Line
Interface
Sensor
2x incremental encoder I/F
Interface
Control Line
subsystem Position manager (motor shaft angle
Line
Interface
Interface
feedback)
Position
Position
Sensor
Sensor
C2000™ MCUs enable the next generation of low-cost, dual-axis servo drives I 3 July 2020
Ext SyncIn
(optional)
Master
Phase reg SyncIn
En
F=0° EPWM1A
CTR=zero EPWM1B
CTR=CMPB
X
1 SyncOut
Slave
Phase reg SyncIn
En Slave
F=0° EPWM2A EPWM1A EPWM2A EPWM3A
Phase reg SyncIn
CTR=zero EPWM2B En
CTR=CMPB F=0° EPWM4A VAB
X
CTR=zero EPWM4B VCD
2 SyncOut
CTR=CMPB VEF
X
Slave 4 SyncOut EPWM1B EPWM2B EPWM3B
Phase reg 3 phase motor
SyncIn
En Slave
F=0° EPWM3A
Phase reg SyncIn
CTR=zero EPWM3B En
CTR=CMPB F=0° EPWM5A
X
3 phase inverter #1
3 CTR=zero EPWM5B
SyncOut
CTR=CMPB
X
5 SyncOut
3 phase inverter #2
Let’s have a closer look at how the configuration of three-phase inverters, as shown in Figure 3, you
the F28004x series enables the control of two servo can see that only six of the PWM modules are
motors concurrently. Several of the key features required: the F28004x still has two PWM pairs
supporting dual axis applications are highlighted in available. Wouldn’t these two pairs be particularly
Figure 2 below. handy if the F28004x was also applying its control
capability to a power factor correction (PFC) circuit
Inverter actuation through C2000
that was generating the high-voltage DC bus for
fourth-generation ePWM modules
the inverter? What if you applied the extra PWMs
A common two-level three-phase inverter used for a to the generation of precision clocking in support
permanent magnet synchronous motor (PMSM) or of position manager solutions for absolute encoder
an alternating current induction (ACI) motor requires interfaces? Or possibly for braking functions?
two switches in a half-bridge configuration on each
With a 100MHz instruction execution frequency,
of the three legs.
or SYSCLK, the F28004x can update the PWM
The pulse-width modulators (PWMs) act as
time-base settings at that frequency for a PWM
complementary pairs to ensure the correct
resolution of 10ns. If you need more precise control
management of the high- and low-side switches
in higher-speed switching scenarios, a 150ps
of one leg.
high-resolution step is available when using the
High-performance deadband features of the PWMs high-resolution PWM (HRPWM) features. With the
are especially helpful here to avoid shoot-through. advent of GaN and SiC inverter switches featuring
Each enhanced PWM (ePWM) module on the very low 12.5ns or smaller deadband periods, the
F28004x device contains a pair of complementary high-resolution deadband capabilities of HRPWMs
PWM generating timers. When supporting two helps dramatically minimize phase-voltage
C2000™ MCUs enable the next generation of low-cost, dual-axis servo drives I 4 July 2020
ringing, sinusoidal distortions and electromagnetic same time. Only two ADCs would require additional
interference. sampling, or the CPU would have to algorithmically
derive the third phase value, potentially introducing
Customizable inverter protection errors in the control and increasing the latency in
through flexible PWM trip capability CPU field-oriented control (FOC) processing. The
Placing the PWM outputs into a known protected three 12-bit ADCs can complete the sampling and
state using the ePWM trip-zone capability protects conversions concurrently in only 290ns.
the inverter. This feature can be particularly useful if Also consider that each of the three F28004x ADCs
you need a torque-off condition when using the trip deliver these 3.5MSPS while also delivering 11.1
in one-shot mode. effective number of bits (ENOB) of dynamic range.
Applying the supported cycle-by-cycle tripping Because of the flexible start-of-conversion triggering
mechanisms may allow even more sophisticated ability, the same three ADCs can alternately sample
ways to keep the equipment running without the three phases of each motor’s current. By
completely shutting down. In addition, there are suitably staggering the start of conversion for each
multiple potential sources for driving a PWM trip. motor, the time it takes to close the current loop for
These sources include an external signal for on-chip a dual-axis system is not double the length of time
qualification and inversion as well as integrated, needed to complete a single current loop. In fact,
high-speed analog comparators and on-chip sigma- the loop time is the same, whether supporting single
delta filter comparators. As many as eight channels or dual axes.
of trip input and PWM crossbar resources are
available, so it’s possible to reserve four channels of As many as 21 analog
trips for each of the two inverters. Every F28004x multiplexed inputs
PWM trip module also includes a selection of Each ADC has at least nine multiplexed analog
Boolean logic configurations in the digital compare input options on the 100-pin quad flat package
module that can further qualify the trip action. (QFP) and at least four potential analog inputs on
the 7mm-by-7mm 56-pin quad flat no-lead (QFN)
High-performance analog conversion
package. This configuration provides flexibility to
of three phases concurrently
support the interleaved three-phase sampling of at
Reducing the overall current-loop time is critical least four different sets of current and/or voltage
for high-performance servo control. The analog- sensing, even on the tiniest device in the F28004x
to-digital (ADC) conversion time has a significant series, with several additional analog inputs for DC
impact on the total current-loop time. It would bus, temperature monitoring and perhaps other less
seem like sampling each motor-phase current time-critical signals.
on two motors would dominate the current-loop
time. However, the high-performance ADCs on the Four sigma-delta filters
F28004x include many features that minimize the The F28004x supports dual axes in high voltage
impact on a dual-motor, dual-current loop. systems as well. When delta-sigma modulators are
For example, the F28004x has three ADCs that can used to sense motor-phase currents, the resulting
use a common start-of-conversion trigger, enabling digital signals cross the air gap to the cold-side
the measurement of all three phases at precisely the where they must be filtered for use in the control
C2000™ MCUs enable the next generation of low-cost, dual-axis servo drives I 5 July 2020
algorithms. TI’s AMC130x delta-sigma modulators Dual feedback paths of load
are a good option but still require filtering to use positions through absolute
them for motion control. Like previous MCUs, the encoder protocols
F28004x series features digital sinc filtering on-
The position manager solutions for absolute
chip to support these external ADCs. In fact, with
encoders leverage a peripheral block on the
four total channels of the digital filters on-chip,
F28004x and other C2000 MCUs called the
it’s possible to route two phases of the sampled
configurable logic block (CLB). The CLB works with
current information of each motor directly to the
other peripherals on-chip to create more valuable
F28004x. In this case, the CPU can use the two
functions that otherwise might require external logic
input phases to algorithmically derive the third phase
devices such as a complex programmable logic
values. Recall that each sigma-delta input channel
device (CPLD) or a field-programmable gate
includes a parallel digital comparison path that when
array (FPGA).
configured can trip the PWMs in
In position manager solutions, coupling the CLB
overcurrent situations.
with a serial port creates solutions for EnDat2.2,
Motor shaft position feedback bidirectional/serial/synchronous (BiSS), Tamagawa
through two eQEPs T-format and other serial encoder standards. The
Whether it’s a dual-channel motor-shaft position CLB on the F28004x has enough capability to
or dual channels of absolute encoder load-angle implement two channels of most protocols.
C2000™ MCUs enable the next generation of low-cost, dual-axis servo drives I 6 July 2020
T/4 = PWM timing difference between inverters
Double sampling
Motor A
PWM 4, 5, 6
3 Ph samples
In-A1, In-B1, In-C1
Motor B
3 Ph samples
In-A2, In-B2, In-C2
F28004x ADCs
fs = 4/T
Other processing
F28004x C28
FCL ISR
conversion time will not change. See Figure 4. For example, if the motor B carrier lags motor A by
For a single axis, you can estimate the FCL to a fixed 90 degrees, then the ADC sampling period
complete in less than 1.6µs on the F28004x series, is consistent across both motors but interleaved
which is nearly a full microsecond faster than between them. Using two 100µs carriers, the ADCs
traditional current loops. Even on the lower-cost can sample three phases of motor A at time zero,
device, the closed loop current bandwidth provided three phases of motor B at 25µs, a “double sample”
by FCL remains at 5kHz on a 10kHz carrier. of motor A at 50µs and a double sample of motor B
at 75µs. See Figure 5.
However, this white paper is about using the
F28004x in a dual-axis configuration. Previously, I Each ADC sample and conversion is followed by
described how the F28004x series has the peripheral the C28x CPU performing the FOC algorithm and
capability to support two servo motors at the same updating the PWMs. In this way, the sample-to-PWM
time. If you assume that the ground plane of the update remains very consistent for each execution,
control circuits is not shared with the ground planes whether it’s the first or second sample of motor A or
for a single F28004x to run two independent FCLs Although using shared resources (the ADCs and
in 1.6µs while still supporting the high-control the CPU, for example), there is no contention for
bandwidth and double sampling of each axis. these resources with this scheme. Each current-
The key lies in interleaving the ADC double sampling loop update – and there are four of them happening
between each motor so that the sampling and in one period, T – takes only 1.6µs. All of the
subsequent FOC processing does not need to performance benefits of FCL, like high control
happen back to back. In order to maintain the goal bandwidth and marginal modulation index (M-I)
C2000™ MCUs enable the next generation of low-cost, dual-axis servo drives I 7 July 2020
MCU
Fast current loop support Power supply
>5 KHz closed loop BW
(10 KHz carrier)
available F28004x 2019
Isolated
Isolated
gate Three-
HRPWM Gatedrive
Drive Three-
phase
Fast current loop execution Isolated Phase
Type 4 Isolatedshunt
Shunt invertor
Invertor
dual axis in <1.6µs current buffer
Current Buffer
PWM trip and
DVD
Fluxgate
2x XBAR
Fluxgate
sensors
Beyond the fast current loop
DVD
Sensors
current
>96% of CPU cycles available for loops 3x ADC DS
DSisolated
Isolated
other functions like speed, C28 ADCs
ADCs
12-bit, 3.5 MSPS
position, communications... DSP w/
TMU Sinc filters PM
PM
>96˜µs of 100 µs period available motor
Motor
eQEP (ABZ)
Integrated communications Position
Position
Line sensor
CAN Position manager Line
interface
Sensor
Interface
SPI
Control Line Position
UART/LIN/SCI Position manager Line
interface Position
subsystem Interface sensor
Sensor
So both axes should operate with an modulation for functional safety applications. SafeTI control
index of 93.6% and deliver 5kHz of closed-loop solutions help you get to market quickly with
control bandwidth for a 10kHz PWM carrier safety-critical systems targeting compliance to
frequency. safety standards such as International Organization
Figure 5 illustrates another important point as well. for Standardization (ISO) 26262 and International
In every 100µs PWM period, the CPU executes the Electrotechnical Commission (IEC) 61508. The
FOC for 1µs four times. So for other processing F28004x series is being offered with SafeTI
functions like the speed loop, position loop or quality-managed design packages for
On-chip support functions save software functions. Some of those functions might
A variety of safety-related applications – including Ethernet standards like EtherCAT and Profinet, you
digital power, electric vehicles, industrial machinery, can use the F28004x SPI port to communicate with
industrial processing, medical, automotive, rail TI’s Sitara™ AMIC110 multiprotocol processors.
C2000™ MCUs enable the next generation of low-cost, dual-axis servo drives I 8 July 2020
FSI amplifiers (PGAs) on the F28004x series may not be
the best solution. However, industrial servo drives
The F28004x also introduces a new serial port
certainly do have other analog sensing inputs for
from C2000 MCUs that could be very useful when
which you could apply the PGAs.
expanding to more than two axes. The Fast Serial
Interface (FSI) is a high-speed serial port supporting For example, the PGAs may be able to replace the
up to 200Mbps in each direction in three-wire mode, signal-conditioning path that senses the DC bus
or 100Mbps each in two-wire mode. FSI is meant supply to the inverter. In some cases, the PGAs may
for use in a chip-to-chip configuration and you can be also useful to condition or amplify temperature
daisy-chain multiple F28004x devices together. or other system-monitoring analog inputs. Some
servo drives may include an analog input feature,
The FSI can also support digital communication
for example, to sense a 4-20mA analog signal
across a high-speed reinforced isolator like the
from other sensors or automation equipment. The
ISO74xx family from TI, especially when your
programmable gain feature of the PGAs could be
requirements include low latency, high bandwidth
particularly helpful when gain control is necessary to
and low cost.
improve the dynamic range of the input.
The F28004x series can serve as a real-time
control-loop accelerator in certain servo system Buffered DACs
architectures that may need to use a larger
The F28004x has two buffered 12-bit digital-to-
microprocessor for motion planning, HMI or
analog converters (DACs). The buffered DAC is
an advanced communications manager. The
a general-purpose DAC that can generate a DC
communication bus between the controller and
voltage or AC waveforms such as sine waves,
processor could be a high-speed SPI or FSI.
square waves or triangle waves. Software writes to
Because the communications are serial in nature,
the DAC value register can take effect immediately
you benefit from the minimized board routing
or synchronize with events triggered by the PWM.
requirements and the reduced costs of
A practical example of how to apply the DACs is
signal isolation.
to generate a bias to convert bipolar signals into
DC/DC core power-supply controller acceptable ADC input levels. Another practical use
is to use the DACs to represent an internal digital
For power and cost savings, designs using the
value for external analog monitoring, or to generate
F28004x can take advantage of the integrated 1.2V
carrier excitation signals for resolvers. And for some
switching regulator (DC/DC) controller to generate
industrial drives that need to include more I/O
the core voltage instead of using the on-chip
functions, the DACs could generate programmable
low-dropout regulator. Compared to older Piccolo
analog output signals to signal or control other
devices using an on-chip linear regulator, using the
the DC/DC controller on the F28004x series can equipment nearby.
Based on the precision requirements generally The F28004x has programmable I/O multiplexing
required in the current-sensing path of servo drive and negation, as well as the unique on-chip routing
controllers, the integrated programmable gain provided by the input, output and PWM crossbars.
C2000™ MCUs enable the next generation of low-cost, dual-axis servo drives I 9 July 2020
Given the wealth of analog input possibilities Reducing or eliminating external
available, there may be unused analog inputs on storage devices
the F28004x in some dual-axis cases. For added
The F28004x has several additional features
flexibility, each analog input circuit can also serve as
that can eliminate the need to add an external
a general-purpose digital input.
component for a unique board or system
When you consider the many I/O multiplexing identification. For example, each device includes
options, digital peripherals whose pin assignments a C2000 unique identifier number in bank 0 of the
are selectable, it’s easy to see how it’s possible to one-time-programmable (OTP) flash. This unique
optimize every pin of a given F28004x package. ID contains a 256-bit value that comprises both
This feature is also a big reason why a dual-axis randomly and sequentially coded parts. The first 192
drive system is possible with a package that is bits are random, the next 32 bits are sequential and
limited to only 100-pins. the last 32 bits are a checksum value. The unique ID
The F28004x can route some of the outputs back can also act as a seed for code encryption on
as inputs and do so on-chip – without using physical the device.
pins on the device. In addition, all of the digital For a small amount of persistent OTP data, the
inputs, including outputs routed back in, can qualify F28004x includes two sectors of 2KB (4KB total)
the input filtering for potential glitches. All inputs user-configurable OTP. This OTP memory includes a
can likewise be negated on-chip, thus saving the section that configures the part of the DCSM OTP.
potential need for external inverters when active-low
As part of the security features of the F28004x, it’s
signals need to be seen as active-high logic on-chip.
possible to restrict access to the contents of the
The input, output and PWM crossbars define the OTP.
number and types of signals that can be routed to
You can change the four available factory default
various control functions on the F28004x. These
boot-mode pins on the F28004x by programming
resources enable system features that otherwise
a section of the user-configurable DCSM OTP
would need to happen off-chip, or potentially enable
locations. Possible boot selections are CAN, serial
functions that would not even be possible externally.
communications interface (SCI), SPI, I2C, on-chip
For example, you could take a PWM output channel flash, on-chip random access memory (RAM) or the
(or perhaps more than one channel), and route them 8-bit parallel I/O boot option.
back as an input to the F28004x. The input could
be qualified, negated and run to the PWM trip-zone ERAD for performance monitoring
block for digital comparison to a crossbar-available An new C2000 capability is available with the
signal such as another PWM output signal, with F28004x. The integrated embedded real-time
Boolean logic. The result of that combination could analysis and debugging (ERAD) module enhances
then be the condition that trips the PWMs and debugging and system analysis capabilities with
protects the inverter. This kind of digital protection functions that otherwise might not be possible
would otherwise need to happen with external even with external components. The ERAD module
circuits that would add dollars, not dimes, to the consists of enhanced bus comparator units and
bill of materials. benchmark system event counter units. The
C2000™ MCUs enable the next generation of low-cost, dual-axis servo drives I 10 July 2020
Figure 7. Product portfolio for real-time control.
C2000™ MCUs enable the next generation of low-cost, dual-axis servo drives 11 July 2020
Conclusion References
• Related documents:
Given its system-level integration and performance,
the F28004x and F28002x series offers a new value o Designing the next generation of industrial drive
point for servo drive systems. But with the ability and control systems
to support two servo motor inverters and feedback o Flexible PWMs Enable Multi-Axis Drives,
requirements simultaneously, the value of these Multi-Level Inverters
C2000 controllers quickly doubles. Industrial servo o Simple interfacing to analog and digital position
and AC inverter drive developers who move quickly sensors for industrial drive control systems
to adopt these new capabilities will lead the race to
o A faster current loop pays off in servo motor
the next industrial motor drive market evolution.
control
The quickest way to begin exploring the capabilities
o C2000 functional safety
of these devices is to order the C2000 MCU
F280049C LaunchPad™ development kit from o F28004x product folder
the TI store. To evaluate the performance of the o F28002x product folder
DesignDRIVE FCL see the projects found in
o F28002x brochure with F28004x comparison
C2000 Ware MotorControl SDK.
o Distributed Servo Drive Reference Design
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