TIDA-010056

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

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

Design files & products

Design files

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

TIDUEQ9A.PDF (8984 K)

Reference design overview and verified performance test data

TIDRZV0.PDF (443 K)

Detailed schematic diagram for design layout and components

TIDRZV1.PDF (299 K)

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

TIDRZV2.PDF (295 K)

Detailed overview of design layout for component placement

TIDRZV4.ZIP (4526 K)

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

TIDCFI2.ZIP (409 K)

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

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 temperature sensors

TMP2351C analog temperature sensor, 10 mV/C

Data sheet: PDF | HTML
BLDC drivers

DRV8350R102-V max 3-phase smart gate driver with buck regulator

Data sheet: PDF | HTML
Current sense amplifiers analog output

INA18026V, 350kHz current sense amplifier

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

TPS709150-mA, 30-V, ultra-low-IQ, low-dropout voltage regulator with reverse current protection and enable

Data sheet: PDF | HTML
MSP430 microcontrollers

MSP430FR235524-MHz 105-C integrated analog microcontroller with 32-KB FRAM, Op-Amps/PGAs, 12-bit DACs, 12-bit AD

Data sheet: PDF | HTML
N-channel MOSFETs

CSD19536KTT100-V, N channel NexFET™ power MOSFET, single D2PAK, 2.4 mOhm

Data sheet: PDF | HTML

Start development

Software

Firmware

TIDA-010056 Firmware — TIDCFI3.ZIP (923 K)

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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
More literature TIDA-010056 Firmware Jun. 13, 2019

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