TIDA-00436 Reference Design

Texas Instruments

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

Description

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 SourceHardware 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 ControlTPS54061 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
Applications
  • Cordless handheld garden tool
  • DC-input BLDC motor drive
  • HVAC motor control
  • 2-wheeler & 3-wheeler traction drive
Product Categories
  • Amplifiers

Parts

Part Number Name Companion Part
DRV8303 DRV8303 Buy Datasheet
LMT84 LMT84 Buy Datasheet
OPA2374 OPA2374 Buy Datasheet
TMS320F28027 TMS320F28027 Buy Datasheet
TPD4S009 TPD4S009 Buy Datasheet
TPS54061 TPS54061 Buy Datasheet

Bill Of Materials

Download the bill of materials for TIDA-00436 Download

Schematic

Quickly understand overall system functionality.

Download the schematic for TIDA-00436

Test Data

Get results faster with test and simulation data that's been verified.

Download the test file for TIDA-00436

Other Documents

Title Updated Type Size (KB)
TIDA-00436 Gerber 17 Mar 2015 ZIP 537
TIDA-00436 CAD Files 17 Mar 2015 ZIP 7004
TIDA-00436 Layer Plots 17 Mar 2015 ZIP 1094
TIDA-00436 Assembly Drawing 17 Mar 2015 PDF 345
TIDA-00436 BOM 17 Mar 2015 PDF 26
TIDA-00436 Schematic 17 Mar 2015 PDF 717