1-kW/36-V Power Stage for Brushless Motor in Battery Powered Garden and Power Tools Reference Design TIDA-00285 (ACTIVE)

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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 ch NexFET MOSFET™, single SON5x6, 2.2mOhm  MOSFETs  Sample & Buy View Design Kits & Evaluation Modules
DRV8303  Three Phase Pre-Driver with Dual Current Shunt Amplifiers  Motor 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™ 32-bit MCU with 60 MHz, 64 KB Flash, InstaSPIN-FOC  C2000 real-time control MCUs  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  4.7V to 60V Input, 200mA Synchronous Step-Down Converter with Low IQ  Step-down (buck)  Sample & Buy View Design Kits & Evaluation Modules

CAD/CAE symbols

Part # Package | Pins CAD File (.bxl) STEP Model (.stp)
CSD18540Q5B VSON-CLIP (DNK)| 8 Download -
DRV8303 Download -
LMT84 Download
Download
Download Download
OPA2374 Download Download
Download -
TMS320F28027F Download Download
TPD4S009 Download Download
Download Download
Download Download
Download Download
TPS54061 Download

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Technical Documents

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User guides (1)
Title Type Size (KB) Date
PDF 8532 02 Feb 2015
Design files (6)
Title Type Size (KB) Date
ZIP 1119 12 Feb 2015
ZIP 6720 12 Feb 2015
PDF 1750 12 Feb 2015
ZIP 192 12 Feb 2015
PDF 22 12 Feb 2015
PDF 716 12 Feb 2015
Related Tools & Software

Design Kits & Evaluation Modules  ( 1 )

Name Part Number Tool Type
C2000 Piccolo MCU F28027F LaunchPad™ development kit  LAUNCHXL-F28027F  Evaluation Modules & Boards 

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