TIDM-1003

Low Voltage, 50A Sensorless FOC Reference Design for PM or BLDC Motors

TIDM-1003

Design files

Overview

The design is a 30V to 54 V Brushless DC motor (BLDC) or Permanent-magnet Synchronous Motors (PMSM) controller for low voltage, high current, high power ebike, power tool, fan, and pump applications. The design uses the Texas Instruments UCC27211D MOSFET drivers, CSD19506KCS 80V NexFET™ power MOSFETs, TMS320F28027F MCU with InstaSPIN™ technology, TPS54360 buck converter, and LDOs. The design utilizes InstaSPIN-FOC technology to identify and tune PMSM or BLDC motor parameters, as well as control motor speed via an external throttle. Overall, the design focuses on demonstrating highly efficient control of high power, low voltage BLDC or PMSM motors.

Features
  • Up to 500W power stage with sensorless FOC based InstaSPIN for BLDC motor, efficiency: >90% over full input range
  • 30 V to 54 V input voltage range, 50A peak output current capability
  • Full protection features, includes Over Current Protection (OCP), Over/Under Voltage Protection (OVP/UVP), over load, under load, lost phase, phase unbalance, stall, motor over temperature, power module over temperature, lost communication
  • Automatic motor parameter identification
  • High performance speed control includes high trajectory changes and speed reversal capability using InstaSPIN-FOC
  • Flying start capability to synchronize to already moving motor

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.

TIDUD29.PDF (3048 K)

Reference design overview and verified performance test data

TIDCDR0.ZIP (34587 K)

Detailed schematic diagram for design layout and components

TIDRRD9.PDF (440 K)

Detailed schematic diagram for design layout and components

TIDRRE0.PDF (31 K)

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

TIDRRE1.PDF (210 K)

Detailed overview of design layout for component placement

TIDRRE3.ZIP (1338 K)

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

TIDCDJ4.ZIP (312 K)

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

TIDRRE2.PDF (2386 K)

PCB layer plot file used for generating PCB design layout

Products

Includes TI products in the design and potential alternatives.

C2000 real-time microcontrollers

TMS320F28027FC2000™ 32-bit MCU with 60 MHz, 64 KB flash, InstaSPIN-FOC

Data sheet document-pdfAcrobat PDF
C2000 real-time microcontrollers

TMS320F28027F-Q1Automotive C2000™ 32-bit MCU with 60 MHz, 64 KB flash, InstaSPIN-FOC

Data sheet document-pdfAcrobat PDF
Buck converters (integrated switch)

TPS543604.5V to 60 V Input, 3.5 A Step-Down Converter with Eco-mode

Data sheet document-pdfAcrobat PDF open-in-new HTML
General-purpose op amps

OPA4374Quad, 5.5-V, 6.5-MHz, RRIO operational amplifier

Data sheet document-pdfAcrobat PDF open-in-new HTML
Half-bridge drivers

UCC272114-A, 120-V half bridge gate driver with 8-V UVLO and TTL inputs

Data sheet document-pdfAcrobat PDF open-in-new HTML
Linear & low-dropout (LDO) regulators

LM2940-N1-A, 26-V, high-PSRR, low-dropout voltage regulator

Data sheet document-pdfAcrobat PDF open-in-new HTML
Linear & low-dropout (LDO) regulators

TPS735500-mA, low-IQ, low-dropout voltage regulator with enable

Data sheet document-pdfAcrobat PDF open-in-new HTML
N-channel MOSFETs

CSD19506KCS80-V, N channel NexFET™ power MOSFET, single TO-220, 2.3 mOhm

Data sheet document-pdfAcrobat PDF open-in-new HTML
Noninverting buffers & drivers

SN74LVC3G07-Q1Automotive 3-ch, 1.65-V to 5.5-V buffers with open-drain outputs

Data sheet document-pdfAcrobat PDF

Technical documentation

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Type Title Date
* Design guide Low-Voltage, 50-A Sensorless FOC for BLDC Motors or PMSMs Reference Design Jun. 14, 2017
User guide InstaSPIN-FOC and InstaSPIN-MOTION User's Guide (Rev. I) Oct. 14, 2021

Related design resources

Software development

APPLICATION SOFTWARE & FRAMEWORK
MOTORWARE MotorWare™ Software
DRIVER OR LIBRARY
CONTROLSUITE controlSUITE™ Software Suite: Software and Development Tools for C2000™ Microcontrollers

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