TIDUA05B June   2015  – March 2025

 

  1.   1
  2.   Description
  3.   Resources
  4.   Features
  5.   Applications
  6.   6
  7. System Description
    1. 1.1 Design Overview
    2. 1.2 Analog Sin/Cos Incremental Encoder
      1. 1.2.1 Sin/Cos Encoder Output Signals
      2. 1.2.2 Sin/Cos Encoder Electrical Parameter Examples
    3. 1.3 Method to Calculate High-Resolution Position With Sin/Cos Encoders
      1. 1.3.1 Theoretical Approach
        1. 1.3.1.1 Overview
        2. 1.3.1.2 Coarse Resolution Angle Calculation
        3. 1.3.1.3 Fine Resolution Angle Calculation
        4. 1.3.1.4 Interpolated High-Resolution Angle Calculation
        5. 1.3.1.5 Practical Implementaion for Non-Ideal Synchronization
        6. 1.3.1.6 Resolution, Accuracy, and Speed Considerations
    4. 1.4 Sin/Cos Encoder Parameters Impact on Analog Circuit Specification
      1. 1.4.1 Analog Signal Chain Design Consideration for Phase Interpolation
      2. 1.4.2 Comparator Function System Design for Incremental Count
  8. Design Features
    1. 2.1 Sin/Cos Encoder Interface
    2. 2.2 Host Processor Interface
    3. 2.3 Evaluation Firmware
    4. 2.4 Power Management
    5. 2.5 EMC Immunity
  9. Block Diagram
  10. Circuit Design and Component Selection
    1. 4.1 Analog Signal Chain
      1. 4.1.1 High-Resolution Signal Path With 16-Bit Dual Sampling ADC
        1. 4.1.1.1 Component Selection
        2. 4.1.1.2 Input Signal Termination and Protection
        3. 4.1.1.3 Differential Amplifier THS4531A and 16-Bit ADC ADS8354
      2. 4.1.2 Analog Signal Path With Single-Ended Output for MCU With Embedded ADC
      3. 4.1.3 Comparator Subsystem for Digital Signals A, B, and R
        1. 4.1.3.1 Non-Inverting Comparator With Hysteresis
    2. 4.2 Power Management
      1. 4.2.1 24-V Input to 6-V Intermediate Rail
      2. 4.2.2 Encoder Supply
      3. 4.2.3 Signal Chain Power Supply 5 V and 3.3 V
    3. 4.3 Host Processor Interface
      1. 4.3.1 Signal Description
      2. 4.3.2 High-Resolution Path Using 16-Bit Dual ADC ADS8354 With Serial Output
        1. 4.3.2.1 ADS8354 Input Full Scale Range Output Data Format
        2. 4.3.2.2 ADS8354 Serial Interface
        3. 4.3.2.3 ADS8354 Conversion Data Read
        4. 4.3.2.4 ADS8354 Register Configuration
    4. 4.4 Encoder Connector
    5. 4.5 Design Upgrades
  11. Software Design
    1. 5.1 Overview
    2. 5.2 C2000 Piccolo Firmware
    3. 5.3 User Interface
  12. Getting Started
    1. 6.1 TIDA-00176 PCB Overview
    2. 6.2 Connectors and Jumper Settings
      1. 6.2.1 Connector and Jumpers Overview
      2. 6.2.2 Default Jumper Configuration
    3. 6.3 Design Evaluation
      1. 6.3.1 Prerequisites
      2. 6.3.2 Hardware Setup
      3. 6.3.3 Software Setup
      4. 6.3.4 User Interface
  13. Test Results
    1. 7.1 Analog Performance Tests
      1. 7.1.1 High-Resolution Signal Path
        1. 7.1.1.1 Bode Plot of Analog Path from Encoder Connector to ADS8354 Input
        2. 7.1.1.2 Performance Plots (DFT) for Entire High-Resulation Signal Path
        3. 7.1.1.3 Background on AC Performance Definitions With ADCs
      2. 7.1.2 Differential to Single-Ended Analog Signal Path
      3. 7.1.3 Comparator Subsystem With Digital Output Signals ATTL, BTTL, and RTTL
    2. 7.2 Power Supply Tests
      1. 7.2.1 24-V DC/DC Input Supply
        1. 7.2.1.1 Load-Line Regulation
        2. 7.2.1.2 Output Voltage Ripple
        3. 7.2.1.3 Switching Node and Switching Frequency
        4. 7.2.1.4 Efficiency
        5. 7.2.1.5 Bode Plot
        6. 7.2.1.6 Thermal Plot
      2. 7.2.2 Encoder Power Supply Output Voltage
      3. 7.2.3 5-V and 3.3-V Point-of-Load
    3. 7.3 System Performance
      1. 7.3.1 Sin/Cos Encoder Output Signal Emulation
        1. 7.3.1.1 One Period (Incremental Phase) Test
        2. 7.3.1.2 One Mechanical Revolution Test at Maximum Speed
    4. 7.4 Sin/Cos Encoder System Tests
      1. 7.4.1 Zero Index Marker R
      2. 7.4.2 Functional System Tests
    5. 7.5 EMC Test Result
      1. 7.5.1 Test Setup
      2. 7.5.2 IEC-61000-4-2 ESD Test Results
      3. 7.5.3 IEC-61000-4-4 EFT Test Results
      4. 7.5.4 IEC-61000-4-5 Surge Test Results
  14. Design Files
    1. 8.1 Schematics
    2. 8.2 Bill of Materials
    3. 8.3 PCB Layout Guidelines
      1. 8.3.1 PCB Layer Plots
    4. 8.4 Altium Project
    5. 8.5 Gerber Files
    6. 8.6 Software Files
  15. References
  16. 10About the Author
    1.     Recognition
  17. 11Revision History

Differential Amplifier THS4531A and 16-Bit ADC ADS8354

The two primary circuits, required to maximize the performance of a high-precision, successive approximation register (SAR) ADCs, are the input driver and the reference driver circuits. For details on selecting the amplifier, refer to the ADS8354 datasheet, Section 9.1.

The THS4531A has been minded to work in combination with the ADS8354. Indeed, the common mode or DC-level of the input signal (2.5 V nominal) is provided to the THS4531A directly from the reference output of the ADS8354 itself to minimize potential offset and drift errors.

The differential input full scale range of the ADS8354 was configured to ±2 × VREF. With the reference voltage of VREF = 2.5 V, this yields a FSR of ±5 V. The maximum Sin/Cos encoder’s differential input voltage is 1.2 VPP. A voltage of higher than 1.35 VPP should still be detected as failure. A safety margin of 50% is added to the maximum peak-to-peak voltage, which is then 1.8 VPP. To match the ADC full-scale input range, the gain of the THS4531A should be 5.5. However, to remain in the linear output voltage range of the THS4531A at a 5-V supply, which is at least 0.25 to 4.8 V, the gain should be reduced by around 10%, hence the ideal differential amplifier gain would be 5.

To ensure the minimum gain error and especially drift between the channels, high-precision, matched resistors with 0.1% accuracy and 2-ppm/K temperature drift are required. To minimize noise, the feedback resistors should be chosen in the lower kΩ range (see Section 1.4).

A precision matching resistor divider is used to keep potential gain errors as small as possible. Refer to the MPMT10015001AT1 datasheet for details.

Due to the gain of 5, a typical 1-VPP input signal leverages around 50% of the ADC full-scale range (FSR), which results in a loss of 1-bit of precision, therefore yielding an equivalent 15-bit resolution. The lower input voltage of 0.6 VPP will leverage around 25% of the FSR, which equals typically 14-bit resolution.

Figure 4-5 shows the schematics of the high-precision analog signal path; the matched gain setting resistors are R18, R27, R30, and R37.

The series 10-Ω resistors R21, R25 and the 2.2-nF capacitor C29 (R33, R36, and C39 for ADS8354 channel B) from the anti-aliasing filter. The filter capacitor C29 (C39), connected across the ADC inputs, filters the noise from the front end drive circuitry, reduces the sampling charge injection and provides a charge bucket to quickly charge the internal sample-and-hold capacitors during the acquisition process. As a rule of thumb, the value of this capacitor should be at least 10 times the specified value of the ADC sampling capacitance. For these devices, the input sampling capacitance is equal to 40 pF. The capacitor should be a COG- or NPO-type because these capacitor types have a high-Q, low-temperature coefficient, and stable electrical characteristics under varying voltages, frequency, and time. To avoid amplifier stability issues, 10-Ω series isolation resistors R21, R25 (R31, R39) are used at the output of the amplifiers. For details, refer to the Section 9.1 of the ADS8354 datasheet.

To minimize the impact of an offset drift of the ADC reference REFIO_A and REFIO_B, the ADC references are used to bias the common mode output voltage of the THS4531A. To buffer and decouple the VOCM signal at the THS4531A, small RC filters R24/C32 and R35/C42 R28, R29, C36, and C37 are added close to each pin.

The ADS8354 reference voltages REFIO_A and REFIO_B are decoupled with a 10-uF capacitor C36 and C37, respectively and a 0.22-Ω resistor is added in series to avoid high-frequency oscillations.

To optimize the layout for cross-talk with minimum use of via for the critical signals A+, A– and B+, B–, the following connections have been made.

  1. The differential input signal A (A+, A–) has been inverted at the input of the THS4531A and fed into the ADS8354 input channel B.
  2. The differential output signal of the THS4531A, B+ and B– have been connected inverted to the ADS8354 input pins AINP_A to B– and AINM_A to B+

This results in the following hardware relationship: The ADS8354 channel B equals the inverted Sin/Cos encoder signal A; the ADS8354 channel A equals the inverted Sin/Cos encoder signal B.

TIDA-00176 Sin and Cos Signal Chain With Dual THS4531A and ADS8354Figure 4-5 Sin and Cos Signal Chain With Dual THS4531A and ADS8354
Note:

Channels are inverted and swapped for optimum performance layout and minimize the numbers of vias.

To achieve a higher noise immunity with reduced bandwidth, a capacitor of 10 pF (1% or better) or higher, pending desired bandwidth is recommend in the feedback path in parallel to the 5 kΩ. See Section 4.5.

The configuration of the ADS8354 registers through serial interface is explained in Section 4.3.