TIDA-00774

18V/1kW, 160A Peak, >98% Efficient, High Power Density Brushless Motor Drive Reference Design

TIDA-00774

Design files

Overview

The TIDA-00774 is a 1kW drive for a three-phase brushless DC (BLDC) motor in power tools operating from a 5-cell Li-ion battery with a voltage up to 21 V. The design is a 65mm x 60mm compact drive, implementing sensor-based trapezoidal control. The design takes advantage of TI's MOSFET Power Block technology, which integrates two FETs in half-bridge configuration into a single SON 5x6 package, enabling very high power density. The design uses two Power Blocks in parallel and delivers 50-ARMS continuous (120-A peak for 3 second, 160-A peak for 1 second) winding current. The MOSFET power block with minimum parasitic inductance and the current controlled gate driver with slew rate control helps in effective MOSFET paralleling and reduces switching spikes. The current sensing is done by monitoring MOSFET VDS. The board provides cycle by cycle over current and short circuit protection.

Features
  • Operates at voltage ranging from 6-V to 21-V (5s li-ion battery) delivering 50-ARMS continuous (120A peak for 3s, 160-A peak for 1s) winding current 
  • Inverter drive efficiency > 98.5%
  • Current sensing by monitoring and amplifying the VDS of MOSFET
  • Effective MOSFET paralleling with excellent dynamic current sharing
  • 18V/680W, 33 A RMS support without heat sink
  • Cycle-by-cycle overcurrent and short circuit protection by VDS sensing

Design files & products

Design files

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

TIDUCL0.PDF (6329 K)

Reference design overview and verified performance test data

TIDRQT8.PDF (1270 K)

Detailed schematic diagram for design layout and components

TIDRQT9.PDF (60 K)

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

TIDRQU0.PDF (261 K)

Detailed overview of design layout for component placement

TIDRQU2.ZIP (3026 K)

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

TIDCDE6.ZIP (306 K)

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

TIDRQU1.PDF (2091 K)

PCB layer plot file used for generating PCB design layout

Products

Includes TI products in the design and potential alternatives.

Analog temperature sensors

LMT87±2°C 2.7V to 5.5V analog output temperature sensor with -13.6 mV/°C gain

Data sheet document-pdfAcrobat PDF open-in-new HTML
Brushless DC (BLDC) motor drivers

DRV832365-V max 3-phase smart gate driver with current shunt amplifiers

Data sheet document-pdfAcrobat PDF open-in-new HTML
Buck converters (integrated switch)

TPS540614.7V to 60V Input, 200mA Synchronous Step-Down Converter with Low IQ

Data sheet document-pdfAcrobat PDF open-in-new HTML
MSP430 microcontrollers

MSP430F513225 MHz MCU with 8KB Flash, 1KB SRAM, 10-bit ADC, comparator, DMA, 16-bit High Resolution timer

Data sheet document-pdfAcrobat PDF open-in-new HTML
Power blocks

CSD88584Q5DC40-V, N channel synchronous buck NexFET™ power MOSFET, SON 5 mm x 6 mm Dual-Cool™ power block, 50 A

Data sheet document-pdfAcrobat PDF

Start development

Software

Firmware

TIDA-00774 Firmware – TIDCDE7.ZIP (4407 K)

Technical documentation

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Type Title Date
* Design guide 18V/1kW, 120APEAK, 98.5 % Efficient, Compact Brushless Motor Drive Design Guide Nov. 09, 2016
Technical article Demand for higher power density drives innovative power tool solution May 23, 2017
More literature TIDA-00774 Firmware May 11, 2017

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