1-kW/36-V Power Stage for Brushless Motor in Battery Powered Garden and Power Tools Reference Design

(ACTIVE) TIDA-00285

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Key Document

Description

This reference design is a power stage for brushless motors in battery-powered garden and power tools rated up to 1 kW. The power stage operates from a 10-cell lithium-ion battery with a voltage range from 36 to 42 V. The design uses CSD18540Q5B NexFETs featuring a very low drain-to-source resistance (RDS_ON ) of 1.8 mΩ in a SON5x6 SMD package, which results in a very small form factor of 57 × 59 mm. The three-phase gate-driver DRV8303 is used to drive the three-phase MOSFET bridge, which can operate from 6 to 60 V and support programmable gate current with maximum setting of 2.3-A sink / 1.7-A source. The power stage can be configured for a single-shunt or three-shunt current sensing. The design supports sensorless control for brushless DC (BLDC) and permanent magnet synchronous motors (PMSM) using trapezoidal control or field oriented control (FOC). The C2000™ Piccolo™ LaunchPad™ is used with the power stage to implement InstaSPIN™-FOC using the motor current and voltage feedback. The corresponding test report evaluates the thermal performance of the board and overcurrent protection features such as cycle-by-cycle control and latch control of the DRV8303.

Features
  • 1-kW Power Stage with Field Oriented Control for Permanent Magnet Synchronous Motors, Designed to Operate from 10-Cell Li-Ion Battery Voltage Ranging from 30 to 42 V
  • Delivers up to 30-A RMS Continuous Motor Current with an Airflow of 400 LFM
  • Small PCB Form Factor of 57 × 59 mm using 60- V/400-A PEAK, 1.8-mΩ RDS_ON, SON5x6 Package MOSFETs for Power Stage
  • Uses DRV8303 Three-Phase Gate Driver, Which Can Operate from 6 to 60-V Input, Supporting Programmable Gate Current With Maximum Setting of 2.3-A Sink / 1.7-A Source
  • Overcurrent Protection Configurable for Cycle-by- Cycle Control or Latch Shutdown
  • Designed to Operate at an Ambient Temperature of –20°C to 55°C

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TI Devices (7)

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Part Number Name Product Family Sample & Buy Design Kits & Evaluation Modules
CSD18540Q5B  60V, N-Channel NexFET™ Power MOSFET   Power MOSFET  Sample & Buy View Design Kits & Evaluation Modules
DRV8303  Three Phase Pre-Driver with Dual Current Shunt Amplifiers  Brushless DC (BLDC) Drivers  Sample & Buy View Design Kits & Evaluation Modules
LMT84  1.5V-Capable, 10 uA Analog Output Temperature Sensor in SC70 and TO-92  Temperature Sensors  Sample & Buy View Design Kits & Evaluation Modules
OPA2374  Dual 6.5MHz, 585uA, Rail-to-Rail I/O CMOS Operational Amplifier  Operational Amplifiers (Op Amps)  Sample & Buy View Design Kits & Evaluation Modules
TMS320F28027F  Piccolo Microcontroller with InstaSPIN-FOC  Real-time Control  Sample & Buy View Design Kits & Evaluation Modules
TPD4S009  4-Channel ESD Solution for High-Speed Differential Interface  Circuit Protection  Sample & Buy View Design Kits & Evaluation Modules
TPS54061  Wide Input 60V, 200mA Synchronous Step-Down DC-DC Converter with Low IQ  Step-Down (Buck)  Sample & Buy View Design Kits & Evaluation Modules

Technical Documents

View the Important Notice for TI Designs covering authorized use, intellectual property matters and disclaimers.

User guides (1)
Title Abstract Type Size (KB) Date Views TI Recommends
PDF 8532 02 Feb 2015 443
Design files (6)
Title Abstract Type Size (KB) Date Views
ZIP 1119 12 Feb 2015 199
ZIP 6720 12 Feb 2015 151
PDF 1750 12 Feb 2015 186
ZIP 192 12 Feb 2015 96
PDF 22 12 Feb 2015 143
PDF 716 12 Feb 2015 790
Related Tools & Software

Design Kits & Evaluation Modules (1)

Name Part Number Tool Type
InstaSPIN™-FOC enabled C2000 Piccolo MCU F28027 LaunchPad Development Kit  LAUNCHXL-F28027F  Evaluation Modules & Boards 


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