Efficient Motor Control Solutions: High Performance Servo Control Reference Designs and Systems Applications

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Today’s Agenda

Motor control applications and target markets

Motor operation and construction

Motor control strategies

Feedback sensors and circuits

Power and isolation

ADI high performance servo control FMC board

Using the ADI high performance servo FMC board with Xilinx® FPGAs and Simulink®

4

Objectives

Provide insight into the operation of electric motor drive systems and show where ADI technology adds value to the system

Understand motor control strategies and the challenges of designing efficient motor control applications

Show how some ADI motor control solutions can be used with Xilinx FPGAs

Show how some ADI motor control solutions can be used with Simulink from MathWorks®

5

Motor Control Applications and Target MarketsSection 1

6

Electric Motor Applications

Electric motors are used in a wide range of applications Industrial Medical Transportation Automotive Integrated applications Communications Household appliances

7

Electric Motor Drives

Motor Drive A system that varies the motor electrical input power to

control the shaft torque, speed, or position.

Types of Drives Application specific drive—designed to run a specific

motor in a specific application (e.g., variable speed pump drive).

Standard drive—designed as a general-purpose motor speed controller capable of running a variety of motors within a given power range.

Servo drive—designed to deliver accurate and high dynamic control of position, speed, or torque down to zero speed. Typically used in automation applications.

High performance servos—designed to deliver best in class accuracy and connectivity. Typically used in CNC and pick and place machines.

8

Market Classification in Motor ControlClassification and Categories

High End Servos and CNC

* Different real-time connectivity

* Multiaxis in single controller* Highest

performance AFE/ sensing

* Advanced system architecture

Servos and Premium Drives

* System dependent real-time connectivity

* Single and dual axis in single

controller* Highest

performance AFE/ sensing

* Balanced/cost optimal system

architecture

Standard and Midrange Drives

* Ethernet and field bus connectivity

* Single axis in one controller* Midend

performance AFE/sensing * Cost optimal

system architecture

Application Specific Motor

Control*Simple/system

connectivity* Single axis in one

controller* System dependent

AFE/sensing * Cost optimal end

application architecture

Market Sub Segments in Motor ControlPartners and Systems Value from ADI

9

High End Servos/CNC

ADI + FPGA Vendors Xilinx

Focus ADI Parts:

Isolation (Gate Drivers/Discrete)AD740x + AMP

RDC + SAR ADC Transceivers

Power Accelerometers/Sensors

Servos and Premium Drives

ADI Has Complete Signal Chain + Select Partners

Focus ADI Parts:ASSPs/SHARC/BF

Isolation (Gate Drivers/Discrete)AD740x + AMP

RDC + SAR ADC Transceivers

Power Accelerometers/Sensors

Standard and Midrange Motor Drives

ADI Has Complete Signal Chain + Select Partners

Focus ADI Parts:ASSPs/BF

Isolation (Gate Drivers/Discrete)AD740x + AMPsRDC + SAR ADC

Transceivers Power

Applications Specific Motor Control

ADI Has Part of Signal Chain + Select Partners

Focus ADI Parts:ASSPs / ADuC Family

Isolation (Gate Drivers/Discrete)

AMPsSAR ADC

Transceivers Power

Highest Value for High Performance

FPGA and AFE

10

Market Trends

Save Energy Drive for performance and quality in motor control More than 40% of global energy consumed by motors The requirement for higher system efficiency means

there is a need to move from standard induction machines to permanent magnet motors

Shift from analog to digital control—focus on highest possible efficiency

Impact of Trends Increases need for new performing technologies on:

converters, amplifiers, processors, isolation, power, interfaces

The need for higher controller performance makes room for new technologies like FPGAs and other advanced controllers to be used in motor control systems

11

Electric Motors Operation and ConstructionSection 2

12

Types of Electric Motors

DC Motors Stepper Brushed DC Brushless Permanent Magnet

Brushless DC (BLDC) Permanent Magnet Synchronous Motors

(PMSM)

AC Motors Asynchronous Motors Synchronous Motors

13

Basic Motor Operation

Torque Production Back EMF Generation

..

..

paa

apa

ke

ikT

Magnetization Fa of the armature coil due to ia produces torque that tends to align the coil with the external magnet.

Rotation of the armature results in a change in the flux coupled from the magnet and EMF ea is generated.

14

Motor Flux and BEMF

The total flux picked up by the motor winding depends on the alignment of the coils with the magnetic field.

The flux linked by a coil varies as a sinusoidal function of its alignment angle with the field.

When the coil moves at a constant speed, the coil flux has a cosine waveform.

The back EMF is the rate of change of flux and is a sine waveform.

AC motors are designed to have a sinusoidal flux function—the back EMF magnitude is proportional to the frequency.

The torque generation function is also sinusoidal.

ttedtdt

dtdte

pa

p

aa

pa

.sin..

.sin.

cos.

Field Alignment and Torque Production

15

Torque produced by magnetic forces on the current carrying conductors.

Maximum torque generated when the coil axis is orthogonal to the magnetic field.

In dc motors, the current polarity is switched when the coil reverses alignment.

In ac motors, torque has a sine function with angle.

Maximum torque is produced when the coil current is in phase with the coil back EMF.

Three phase machines generate constant power and torque.

cos.

.sin..sin...sin.

.sin..

mp

mpaa

ma

pa

IT

ttItiteTtIti

tte

16

DC and AC Motor Construction

DC Motor Moving armature coils and fixed

magnets The coil voltage polarity depends

on alignment angle with the magnet

The commutator automatically selects the coils generating positive voltage

AC Motor Fixed stator coils and moving

rotor magnets The coil voltages depend on the

alignment angle with the rotor magnets

Multiple stator windings for smooth torque production

17

Brushless DC and PMSM Motor Construction

BLDC Motor Fixed stator coils and moving

rotor permanent magnets Trapezoidal supply voltage Trapezoidal BEMF Stator flux position commutates

each 60 degrees High core losses Relative simple control algorithm

PMSM Motor Fixed stator coils and moving

rotor permanent magnets Sinusoidal supply voltage Sinusoidal BEMF Continuous stator flux position

variation Lower core losses Complex control algorithm

18

Motor Control StrategiesSection 3

19

Brushed DC Motor Control

Vary the dc supply, and the motor speed will follow the applied voltage

Pulse width modulation Constant amplitude voltage pulses of varying

widths are provided to the motor: the wider the pulse, the more energy transferred to the motor

The frequency of the pulses is high enough that the motor’s inductance averages them, and it runs smooth

A single transistor and diode can control the speed of a dc motor The motor speed (voltage) is proportional to the

transistor ON duty cycle Positive torque only—passive braking

An H-bridge power circuit enables four quadrant control Forward and reverse motion and braking Complementary PWM signals applied to the high

and low side switches in the bridge

A

B C

BLDCCONTROLLER

+

-

HALL

A

HALL

B

HALL

C

Brushless DC Motor Control

20

Brushless dc motors windings generate a trapezoidal back EMF synchronized to the position of the rotor magnet.

Hall effect sensors detect the rotor magnet position and provide signals indicating the “flat top” portion for each winding’s back EMF.

Six switching segments can be identified.

Star Connection Control For any one segment, two windings will be in the

“flat top” portion of the back EMF and a third winding will be switching between a positive and negative output.

Electronic control leaves one winding open circuit, connects one winding to the lower dc rail, and controls the voltage applied to the third winding using PWM.

The fill factor of the applied PWM controls the speed of the motor.

A

B C

BLDCCONTROLLER

+

-

HALL

A

HALL

B

HALL

C

Brushless DC Motor Control

21

Delta Connection Control For any one segment, two windings are

connected to the positive voltage supply and a third winding is connected to the negative voltage supply.

The fill factor of the applied PWM controls the speed of the motor.

The rotation sequence can be reversed by reversing the polarity of the windings.

Sensorless control can be achieved by detecting the zero crossings of the BEMF for each phase

Sensorless control benefits Lower system cost Increased reliability

Sensorless control drawbacks BEMF zero crossings can’t be reliably

detected at low motor speeds

AC Motor Control

22

Volts per Hertz Control Variable frequency drive for applications like

fans and pumps Fair speed and torque control at a

reasonable cost

Sensorless Vector Control Does not require a speed or position

transducer Better speed regulation and the ability to

produce high starting torque

Flux Vector Control More precise speed and torque control, with

dynamic response Retains the Volts/Hertz core and adds

additional blocks around the core

Field Oriented Control Best speed and torque control available for

ac motors The machine flux and torque are controlled

independently

U

V

W

AC MOTORCONTROLLER

+

-

Ia Ib

Spee

d

Field Oriented Control (FOC)

23

Separates and independently controls the motor flux and torque

Applies equally well to dc motors and ac motors and is the reason “dc like” performance can be demonstrated using field oriented control on ac drives

TorqueController

PI

FluxController

PI

Inverse Park

Transform

d,q → α,β

Space Vector PWM

3 Phase Inverter

Forward Clarke

Transform

a,b → α,β

Forward Park

Transform

α,β → d,q

Vsq

Vsd

Vsα

Vsβ

Vsa PWM

Vsb PWM

Vsc PWM

AC Motor

isa

isb

isα

isβ

isd

isq

Vsq

Vsd

VsqRef

VsdRef

_+

+_

VDC

Rotor Flux Angle θ

Field Oriented Control—Clarke

24

The forward Clarke transformation converts a 3-phase system (a, b, c) to a 2-phase coordinate system (α, β).

Forward Clarke transformation

Inverse Clarke transformation

a, α

β

b

c

Isa Isα

Isb

Isc

IsIsβ

Field Oriented Control—Park

25

The forward Park transformation converts a 2-phase system (α, β) attached to the stator reference frame to a 2-phase coordinate system (d, q) attached to the rotor reference frame.

Forward Park transformation

Inverse Park transformation

β

α Isα

Isβ

Is

d

q

θfieldIsd

Isq

Space Vector Modulation

26

Directly transforms the stator voltage vectors from a (α, β) coordinate system to PWM signals

A vector is produced that transitions smoothly between sectors and, thus, provides sinusoidal line-to-line voltages to the motor

The mean vector computed during a PWM period is equal to the desired voltage vector

U V W Vector

0 0 0 U000

0 0 1 U0

0 1 0 U120

0 1 1 U60

1 0 0 U240

1 0 1 U300

1 1 0 U180

1 1 1 U111

27

Feedback Sensors and CircuitsSection 4

28

Current and Voltage Sensing

Shunt Resistor Linear, wide BW, zero offset Power loss at high currents and

no isolation Current Transformer

Isolating AC only with poor linearity at low current

Hall Effect Current Sensor Isolating, dc operation and less expensive

than CT Nonlinearity and zero offset

Nulling Hall Effect Sensor Isolating, dc operation and better linearity

than HE sensor More expensive and zero offset Voltage isolation Used to remove CM signal from dc bus,

motor voltage, and current shunt voltages

Isolating

29

Shaft Position and Speed Sensing Devices

Speed AC and DC tachometers are permanent

magnet generators that produce a voltage proportional to speed.

The ac tachometer output frequency is also proportional to speed.

Commutation (Rotor Angle) Brushless dc motors require low

resolution feedback derived from the motor magnets using Hall effect sensors.

A Hall effect based magnetic encoder generates a pulse train for speed and incremental position.

Precision Shaft Angle Optical encoders with precision pattern

printed on a glass disk provide very high resolution shaft position and speed data.

Resolvers generate sine/cosine relative to position. They are the analog counterpart of the rotary encoder.

30

Sensorless Control

Eliminate mechanical speed/position sensors by calculating feedback signal from other information Often used for rotor position estimation in PMSM and BLDC motors Very useful in estimating rotor flux position in ACIM FOC control In some cases, can provide better results than real sensors

Techniques BEMF detection to estimate rotor position in BLDC motor control Rotor angle detection based on motor model using measured phases currents

and voltages

Problems Variation of motor/model parameters over time, temperature Usually need special handling of low speed/zero speed and/or start-up

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Power and IsolationSection 5

32

Safety and Functional Isolation

Functional isolation protects electronic control circuits from damaging voltages Isolate high voltage output from control circuits

connected to Power_GND Safety isolation protects the user from dangerous

voltages Protects user and electronic circuits International standard apply Typically requires double insulation barrier: single

device with two insulating layers OR two single insulating layer devices in path to EARTH

Isolation options Isolate power circuits from the control and user I/O

circuits Common in “noisy” high power systems Required when there is high BW communications

between control and communications process Isolate power and control circuits from user I/O

circuits Common in low power systems Simplifies signal isolation when there is limited

communications between control and user

33

Motor Control Signal Isolation—Isolated Power Circuit Feedback isolation

Measure winding current using isolating ADC

Isolated RS-485 position data from encoder ASIC

Inverter drive isolation Isolated high- and low-side gate

drivers

DC bus signal isolation Serial I2C ADC for analog signal

isolation Digital isolation of hardware trip

signals

Field Bus isolation Isolate CAN outputs from field bus

network

34

ADI High Performance Servo Control FMC BoardSection 6

35

FPGAs in Motor Control

FPGAs are becoming more popular for motor control Wide integration capabilities Higher performance, reduced latency Cost reduction

FPGAs are used in a large number of industry fields for efficient motor control Industrial servos and drives Manufacturing, assembly, and automation Medical diagnostic Surgical assist robotics Video surveillance and machine vision Power efficient drives for transportation

36

ADI FMC High Performance Servo Board

Purpose Provide an efficient motor control solution for different types of

electric motors Address power and isolation challenges encountered in motor

control application Provide accurate measurement of motor feedback signals FPGA interfacing capability

Added Value Complete control solution showing how to integrate hardware for:

Power Isolation Measurement Control

Increased control flexibility due to FPGA interfacing capabilities Increased versatility to be able to control different types of

motors Example reference designs showing how to use the control

solution with Xilinx FPGAs and Simulink

37

ADI FMC High Performance Servo Board

FMC 12 V or external power Drives motors up to 42 V at 4 A Control signals isolation Current and voltage measurement using

isolated ADCs BEMF zero cross detection for sensorless

control of PMSM or BLDC motors

Connectors for Hall and speed encoders Can drive two BLDC/PMSM/brushed DC

motors simultaneously Can drive one stepper motor Compatible with all Xilinx FPGA platforms

with FMC LPC or HPC connectors Interface for Xilinx 7 series FPGAs XADC

ADI FMC Motor Control Board Block Diagram

38

ADI FMC MOTOR CONTROL

ISOLATED

Motor Driver

L6234

Current + Voltage Sense

AD7401A

Current + Voltage Sense

XADCAD8126 AD8137

Power

ADP2504 ADUM5000

ADP122

IsolationADUM1310

Voltage Translation

ADG3308

BEMF Sense

CMP04

FMC_3.3V

VEXT_DC 12V-42VFLOATING GND REFERENCE

VBUS

FMC_12VFPGA GND REFERENCE

HALL Sensors / Speed Encoder

HALL Sensors / Speed Encoder

HALL / Speed Encoder

HALL / SpeedEncoder

Ia / Ib / It Vbus

U/V/W BEMF

XADC Header

5V_ISO

3.3V_ISO

Motor Driver

L6234

Voltage Translation

ADG3308

Voltage Translation

ADG3308

FMC_M1_PWM

FMC_M2_PWM

FMC_M1_FAULT

FMC_M2_FAULT

IsolationADUM110

IsolationADUM1310

IsolationADUM110

IsolationADUM1310

VBUS

GND_ISO

BLDC / PMSM /

DC / STEPPER

FMCLPC

BLDC / PMSM /

DC / STEPPER

Shunt Resistors

U / V / W

Shunt Resistors

U / V / W

Ia / Ib / It

Ia / Ib / It

39

Key Parts Features That Improve System Performance Efficient Motor Control Prerequisites

High quality power sources Reliable power, control, and feedback signals isolation Accurate currents and voltages measurements High speed interfaces for control signals to allow fast controller response

MeasurementAD7401A 5 kV rms, isolated 2nd order Sigma-Delta modulator

AD8216 High bandwidth, bidirectional 65 V difference amplifier

PowerADuM5000 isoPower® integrated isolated dc-to-dc converter

ADP2504 1000 mA, 2.5 MHz buck-boost dc-to-dc converter

ADP122 Low quiescent current, CMOS linear regulator

IsolationADuM1310 Triple channel digital isolator

ADuM1100 iCoupler® digital isolator

Voltage TranslationADG3308 8-channel bidirectional level translator

40

AD7400A/7401A: 5 kV rms, Isolated 2nd Order Sigma-Delta Modulator Features

High performance isolated ADC 16-bit NMC ±2 LSB (typ) INL with 16-bit resolution 1.5 mV/°C (typ) offset drift

±250 mV differential analog input −40°C to +125°C operating temperature

range 5 kV rms, isolation rating (per UL 1577) Maximum continuous working voltages

565 V pk-pk: ac voltage bipolar waveform 891 V pk-pk: ac voltage unipolar

waveform (CSA/VDE) 891 V: dc (CSA/VDE)

Ideal for motor control and dc-to-ac inverters Shunt resistor current feedback sensing Isolated voltage measurement

External clocked version simplifies synchronization

Product Data Rate Clock SNR ENOB INL PackageAD7400A 10 MHz Internal 80 dB 12.5 ±2 LSB SOIC-16

Gull Wing-8AD7401A 20 MHz External 83 dB 13.3 ±1.5 LSB SOIC-16

41

AD8216: High Bandwidth, Bidirectional 65 V Difference Amplifier Features

±4000 V HBM ESD Ideal for current shunt applications High common-mode voltage range

−4 V to +65 V operating −40 V to +80 V survival 3 MHz bandwidth <100 ns output propagation delay

Gain: 3 V/V Wide operating temperature range

Die: −40°C to +150°C 8-lead SOIC: −40°C to +125°C

Adjustable output offset Excellent ac and dc performance

10 μV/°C offset drift 10 ppm/°C gain drift

Qualified for automotive applications Applications

High-side current sensing in DC-to-DC converters Motor controls Transmission controls Diesel-injection controls Suspension controls Vehicle dynamic controls

42

ADuM5000: Isolated DC-to-DC Converter

Features isoPower® integrated isolated dc-to-dc

converter Regulated 3.3 V or 5 V output Up to 500 mW output power 16-lead SOIC package with >8 mm

creepage High temperature operation

105°C maximum High common-mode transient immunity

>25 kV/μs Thermal overload protection Safety and regulatory approvals

UL recognition 2500 V rms for 1 minute per UL 1577 CSA component accept notice #5A

(pending)

Applications RS-232/RS-422/RS-485 transceivers Industrial field bus isolation Power supply startups and gate drives Isolated sensor interfaces Industrial PLCs

43

ADP2504: 1000 mA, 2.5 MHz Buck-Boost DC-to-DC Converter Features

2.5 MHz operation enables 1.5 μH inductor Input voltage: 2.3 V to 5.5 V Fixed output voltage: 2.8 V to 5.0 V 1000 mA output Boost converter configuration with load

disconnect Power save mode (PSM) Forced fixed frequency operation mode Synchronization with external clock Internal compensation Soft start Enable/shutdown logic input Overtemperature protection Short-circuit protection Undervoltage lockout protection

Applications Wireless handsets Digital cameras/portable audio players Miniature hard disk power supplies USB powered devices

44

ADuM1310: Triple Channel Digital Isolator

Features Low power operation 5 V operation

1.7 mA per channel maximum at 0 Mbps to 2 Mbps

4.0 mA per channel maximum at 2 Mbps to 10 Mbps

3 V operation 1.0 mA per channel maximum at 0 Mbps to

2 Mbps 2.1 mA per channel maximum at 2 Mbps to

10 Mbps Bidirectional communication 3 V/5 V level translation Schmitt trigger inputs High temperature operation

105°C Up to 10 Mbps data rate (NRZ) Programmable default output state High common-mode transient immunity

>25 kV/μs

Applications General-purpose multichannel isolation SPI interface/data converter isolation RS-232/RS-422/RS-485 transceiver Industrial field bus isolation

45

L6234: 3-Phase Motor Driver

Features Supply voltage from 7 V to 52 V 5 A peak current RDSON 0.3 Ω typ value at 25°C Cross conduction protection TTL compatible driver Operating frequency up to 150 kHz Thermal shutdown Intrinsic fast free wheeling diodes Input and enable function for each

half bridge 10 V external reference available

Applications Brushed dc drives BLDC drives PMSM drives

46

Using the ADI High Performance Servo FMC Board with Xilinx FPGAs and SimulinkSection 7

47

ADI High Performance Servo Development Platform Target FPGA Platforms

Xilinx Virtex FPGA platforms Xilinx Kintex FPGA platforms Xilinx Zynq FPGA platforms

Control Algorithms Simulink models for controller ready for code

generation using HDL Coder™ from MathWorks and Xilinx System Generator

Reference design showing BLDC motor speed control

Reference design showing BLDC motor speed and torque control

Simulation and Monitoring Controller simulation and tuning in Simulink ChipScope™ interface for internal signals

monitoring

48

Motor Control Reference Design FPGA Blocks

Motor Controller generated from Simulink 6 State Motor Driver SINC3 Filters for current and voltage

measurement

BEMF position detector Hall position detector ChipScope blocks

Xilinx ML605/KC705/VC707/ZC702 FPGA

FMC LPC

ADI Motor Control Board

Motor Controller

BEMF Position Detector

SINC3 Filters

HALL Position Detector

Isolated Gate Driver M

BLDC

PWM

Isolated ADCs Current Shunts

BEMF Zero Cross

Detectors

HALL Sensors

Voltage Level Translator

Chipscope ICON

Chipscope ILA

6 State Motor Driver

MUX

PWM

Current

Position

Chipscope VIO

49

Speed Control Reference Designs

Speed Control Reference Design Target motor: BLDC Speed control using Hall sensor Sensorless speed control using

BEMF Simulink controller model ChipScope interface for internal

signals monitoring

Implementation Flow

BLDCPID Controller

6 State Motor Driver

Speed Computation

PWM

PositionSpeed

Reference Speed

+

-

Design and Tune the

Motor Controller in

Simulink using the

Xilinx Blockset

Generate the HDL Netlist for the

Simulink Motor Controller using

Xilinx System Generator

Integrate the

Motor Controller HDL Netlist in the

Speed Control Reference Design

Simulink Speed Controller

50

Speed Computation

PID Controller

Edge Detection

Simulink Speed Controller

51

52

Motor Control Reference Designs

Speed and Torque Control Reference Design Target motor: BLDC Speed and torque control Simulink controller model ChipScope interface for

internal signals monitoring

Implementation Flow

BLDCPI Speed Controller

6 State Motor Driver

Speed Computation

Current Reference

PositionSpeed

SpeedReference

+

-PID Current Controller

PWM

Current Computation

Total Current Measurement

Total Current

+ -

Design and Tune the

Motor Controller in

Simulink using

Simulink Native Blocks

Generate the HDL Netlist for the

Simulink Motor Controller using

Xilinx System Generator

Integrate the

Motor Controller HDL Netlist in the

Speed and Torque Control Reference Design

Generate the HDL code for the

Motor Controller using

HDL Coder

Replace in the Simulink model the Motor Controller

with Xilinx Black Boxes

containing the HDL generated by

HDL Coder

Simulink Speed and Torque Controller

53

Speed Computation

PI Speed ControllerCurrent Computation

PID Torque Controller

HDLCODER

Simulink Speed and Torque Controller

54

Simulink Speed and Torque Controller

55

56

Conclusions

The ADI high performance servo development platform showcases a full motor control solution that shows how to integrate all the necessary hardware components for efficient motor control in one system

The FPGA interfacing capabilities provide a high degree of flexibility in developing high performance motor control algorithms

By using the MathWorks simulation and development tools, high performance control algorithms can be developed and simulated on the PC and transferred directly into the FPGA

The ADI motor control reference designs provide a starting point for developing enhanced motor control algorithms using MathWorks and Xilinx FPGAs

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What We Covered

Motor operation and construction Motor control strategies Feedback sensors and circuits Power and isolation ADI high performance servo control FMC board Using the ADI high performance servo FMC board with Xilinx FPGAs

and Simulink

58 Tweet it out! @ADI_News #ADIDC13

Design Resources Covered in This Session

Ask technical questions and exchange ideas online in our EngineerZone™ Support Community Choose a technology area from the homepage:

ez.analog.com Access the Design Conference community here:

www.analog.com/DC13community

Download the motor control reference designs and documentation from the ADI wiki

wiki.analog.com

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Visit the Motor Control Demo in the Exhibition Room Demo: speed and torque control of a BLDC motor Two motors connected through a drive belt—one motor in generator

mode with variable output resistance to simulate load changes on the driving motor

The system’s operation can be completely monitored and controlled through ChipScope

Hardware: ADI servo control FMC board Xilinx ML605 FPGA board 2 × 24 V BLDC motors

This demo board is available for purchase: www.analog.com/DC13-hardware