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TIDA-010056

54-V, 1.5 kW, >99% Efficient, 70x69 mm2 power stage reference design for 3-phase BLDC drives

Design files

TIDA-010056

Design files

Overview

This reference design demonstrates a 1.5-kW power stage for driving a three-phase brushless DC motor in cordless tools operating from a 15-cell Li-ion battery with a voltage up to 63-V. The design is a 70mm x 69mm compact drive, bringing 25-ARMS continuous current at 20-kHz switching frequency without heat sink and with natural convection, implementing sensorbased trapezoidal control. The design achieves optimized MOSFET switching loss and EMI by using a smart gate driver with optimized MOSFET and PCB. The design shows MOSFET operation within the safe operating area using enhanced protections including MOSFET over current and shoot-through protection by VDS monitoring, gate protection, switching voltage spike optimization with slew rate control and over temperature protection.

Features
  • Operates at voltage ranging from 9 V to 63 V (15s li-ion battery) delivering 25 ARMS continuous current, 400-A peak
  • 54 V/1.5 kW, 25 ARMS support without heat sink in a small 70mm x 69mm PCB form factor
  • More than 99% efficiency at 20 kHz trapezoidal control for 54 V/1.5 kW
  • MOSFET over current protection by VDS sensing with response time less than 1-µs with additional 4-µs deglitch time to eliminate false trips
  • Enhanced protection at MOSFET gate including VGS under-voltage, over-voltage, gate to source short circuit and open circuit protections
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A fully assembled board has been developed for testing and performance validation only, and is not available for sale.

Design files & products

Design files

Download ready-to-use system files to speed your design process.

download Design guide — TIDA-010056
TIDUEQ9A.PDF (8984 K)

Reference design overview and verified performance test data

download Schematic — TIDA-010056
TIDRZV0.PDF (443 K)

Detailed schematic diagram for design layout and components

download Bill of materials (BOM) — TIDA-010056
TIDRZV1.PDF (299 K)

Complete listing of design components, reference designators, and manufacturers/part numbers

download Assembly drawing — TIDA-010056
TIDRZV2.PDF (295 K)

Detailed overview of design layout for component placement

download CAD/CAE symbol — TIDA-010056
TIDRZV4.ZIP (4526 K)

Files used for 3D models or 2D drawings of IC components

download Gerber file — TIDA-010056
TIDCFI2.ZIP (409 K)

Design file that contains information on physical board layer of design PCB

download PCB layout — TIDA-010056
TIDRZV3.PDF (1816 K)

PCB layer plot file used for generating PCB design layout

Products

Includes TI products in the design and potential alternatives.

Analog current-sense amplifiers

INA180 — 26V, 350kHz current sense amplifier

Data sheet: PDF | HTML
Analog temperature sensors

TMP235 — 1C analog temperature sensor, 10 mV/C

Data sheet: PDF | HTML
BLDC drivers

DRV8350R — 102-V max 3-phase smart gate driver with buck regulator

Data sheet: PDF | HTML
Linear & low-dropout (LDO) regulators

TPS709 — 150-mA, 30-V, ultra-low-IQ, low-dropout voltage regulator with reverse current protection and enable

Data sheet: PDF | HTML
MOSFETs

CSD19536KTT — 100-V, N channel NexFET™ power MOSFET, single D2PAK, 2.4 mOhm

Data sheet: PDF | HTML
MSP430 microcontrollers

MSP430FR2355 — 24-MHz 105-C integrated analog microcontroller with 32-KB FRAM, Op-Amps/PGAs, 12-bit DACs, 12-bit AD

Data sheet: PDF

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Software

Technical documentation

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Type Title Date
* Design guide 54-V, 1.5 kW, >99% Efficient, 70x69 mm^2 Power Stage Reference Design (Rev. A) Jul. 31, 2019

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