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TIDA-00436

36V/1kW Brushless DC Motor Drive with Stall Current Limit of <1us Response Time Reference Design

Design files

TIDA-00436

Design files

Overview

This reference design is a power stage for brushless motors in battery-powered garden and power tools rated up to 1 kW, operating from a 10-cell lithium-ion battery with a voltage range from 36 to 42 V. The design uses 60V, N-channel NexFETsTM 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 PCB form factor of 57 × 59 mm. The three-phase gate-driver is used to drive a three-phase MOSFET bridge, which can operate from 6 to 60 V and supports programmable gate current with maximum setting of 2.3-A sink / 1.7-A source. The C2000™ Piccolo™ LaunchPad™ LAUNCHXL-F28027 is used along with this power stage and 120 degree trapezoidal control of BLDC motor with Hall sensors is implemented in software. The cycle by cycle current limit feature in the gate-driver protects the board from excessive current that is caused during motor stalls, by limiting the maximum current allowed in the power stage to a safe level.

Features
  • 1-kW Power Stage with Hall sensor based Trapezoidal Control for Brushless DC Motor implemented on TMS320F28027 MCU.
  • Designed to Operate from 10-Cell Li-Ion Battery Voltage Ranging from 30-V to 42-V
  • Delivers up to 32-ARMS Continuous Motor Current With an Airflow of 400 LFM
  • Small PCB Form Factor of 57mm x 59 mm using CSD18540Q5B 60-V/400-Apeak, 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
  • Hardware Cycle-by-Cycle Overcurrent limit  with Configurable Threshold for motor stall protection
  • Provision for Sense Feedback of Individual Phase Voltage, DC Bus Voltage, DC Bus current sense and Low-Side Current sense on Each Phase for Sensorless Control
  • TPS54061 based 3.3-V/0.15-A Step-Down Buck Converter for Powering MCU
  • Designed to Operate at an Ambient Temperature of–20°C to 55°C
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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-00436
TIDU852B.PDF (10446 K)

Reference design overview and verified performance test data

download Schematic — TIDA-00436
TIDRDH3.PDF (717 K)

Detailed schematic diagram for design layout and components

download Bill of materials (BOM) — TIDA-00436
TIDRDH4.PDF (26 K)

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

download Assembly drawing — TIDA-00436
TIDRDH5.PDF (345 K)

Detailed overview of design layout for component placement

download CAD/CAE symbol — TIDA-00436
TIDRDH7.ZIP (7004 K)

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

download Gerber file — TIDA-00436
TIDC976.ZIP (537 K)

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

download PCB layout — TIDA-00436
TIDRDH6.ZIP (1094 K)

PCB layer plot file used for generating PCB design layout

Products

Includes TI products in the design and potential alternatives.

AC/DC & DC/DC converters (integrated FET)

TPS54061 — 4.7V to 60V Input, 200mA Synchronous Step-Down Converter with Low IQ

Data sheet: PDF | HTML
Analog temperature sensors

LMT84 — 1.5V-Capable, 10 uA Analog Output Temperature Sensor in SC70 and TO-92

Data sheet: PDF | HTML
BLDC drivers

DRV8303 — 65-V max 3-phase gate driver with current shunt amplifiers & SPI

Data sheet: PDF | HTML
C2000 real-time microcontrollers

TMS320F28027 — C2000™ 32-bit MCU with 60 MHz, 64 KB flash

Data sheet: PDF
C2000 real-time microcontrollers

TMS320F28027-Q1 — Automotive C2000™ 32-bit MCU with 60 MHz, 64 KB flash

Data sheet: PDF
ESD protection diodes

TPD4S009 — Quad 0.8-pF, 5.5-V, ±8-kV ESD protection diode with VCC pin for High Speed Interfaces

Data sheet: PDF | HTML
General-purpose op amps

OPA2374 — Dual, 5.5-V, 6.5-MHz, RRIO operational amplifier

Data sheet: PDF | HTML
MOSFETs

CSD18540Q5B — 60-V, N channel NexFET™ power MOSFET, single SON 5 mm x 6 mm, 2.2 mOhm

Data sheet: PDF | HTML

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Software

Technical documentation

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Type Title Date
* Design guide 36-V, 1-kW BLDC Motor Drive With Stall Current Limit of Less Than 1-µs Response (Rev. B) May 12, 2016

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