AN/H-4

Smart-Power H-Bridges Control the Speed and Torque of DC Brush Motors

Power Products Data Device Corporation

Designing motion control systems can be done quickly and easily with DDC's PWR-82340 and PWR-82341 SmartPower H-Bridges, which will drive permanent magnet DC brush motors. The same Smart-Power H-Bridge, due to its universal design, can be used in either a velocity loop for speed control, or a current loop for torque control depending on the user's configuration. Figures 1 and 2 show block diagrams of these two types of control systems.

deliver pulse widths from both the A and B outputs (pins 4 & 7) that will be a function of the sign and amplitude of the error signal. (Important Note: you must clamp these outputs to prevent exceeding the allowable input voltage range of the PWR82341. You can accomplish this with 12V zeners VR1 & VR2 and resistors R18 & R19.) Furthermore, the user can change the triangle wave threshold voltages and oscillating frequency depending upon the

external resistors R8, R9, R10 and capacitor C2 that they select. The user provides current limiting by connecting a fractional ohm current sense resistor R22 (selected to prevent exceeding the current capability of the PWR-82341) between the VSS pins of the PWR-82341 and the high-voltage power return. The circuit will monitor the voltage drop across this resistor and provide pulse-by-pulse current limiting when the motor current exceeds the preset trip

Speed Control
The PWR-82341 can be used to develop a 100V, 5A bi-directional DC motor speed control with just a few external components. The velocity loop can be closed with the help of a Unitrode UC1637 Switched Mode Controller and a tachometer as seen in Figure 3. The UC1637 is a pulse width modulation device that includes a sawtooth generator, error amplifier, current limit, and two PWM comparators for dead-band control. To obtain speed control, the user applies a command voltage from potentiometer R2 to the noninverting input (pin 15) of the error amplifier. The PWM will

ENABLE
+VBUS

V+ SPEED COMMAND SPEED REGULATOR PWM GENERATOR DIGITAL CONTROL AND PROTECTION

A PHASE A GATE DRIVE

B PHASE B GATE DRIVE

V-

PULSE BY PULSE ILIMIT

RSENSE

FIGURE 1. BIDIRECTIONAL SPEED CONTROL

SMART POWER H-BRIDGES CONTROL THE SPEED AND TORQUE OF DC BRUSH MOTORS

point. By using a tachometer you can provide a velocity feedback to the inverting input of the error amplifier (pin 16). This feedback will vary the pulse widths from the UC1637 outputs based on the relationship between the tach signal and the speed command, to either increase or decrease the duty cycle of the MOSFETs in the PWR-82341. Hence, an increase in speed command will increase the on-time of a pair of MOSFETs in the PWR-82341, which will increase the power applied to the motor; thereby, increasing the speed.

back signal coming from the current sense amplifier (U3). This time we get current sensing right at the motor leads by using a fractional ohm sense resistor R1. We
ENABLE

base component selection in this section of the circuit on the maximum operation bus voltage (Vbus max) seen at the PWR82340 and the maximum load current
+VBUS

CURRENT COMMAND

SPEED REGULATOR

+
COMMAND AMPLIFIER

PWM GENERATOR

DIGITAL CONTROL AND PROTECTION

RSENSE A M B

PHASE A GATE DRIVE PULSE BY PULSE I LIMIT

PHASE B GATE DRIVE

Torque Control
If you require motor torque control instead of velocity, then the loop must be closed on current as seen in Figure 4. The same UC1637 Switched Mode Controller will be used again. Here the user feeds a current command into command amplifier (U5), which sums it with the current feed+15 VDC 15V RTN +28 VDC R1 5K R4 10K R8 7.5K 6 +VTH +VS R9 5K 3 -V TH 9 -B IN SPEED CONTROL R2 5K R5 1.2K R10 7.5K
AOUT 4

ABSOLUTE VALUE

V+ CURRENT MONITOR ISENSE Amp VOFFSET ADJUST

FIGURE 2. TORQUE CONTROL

R14 2.5K 14 S.D.

R15 7.5K

C4 0.01F

C6 0.01F 4 V+ 6 VLPI VCC 30, 31 VCC 23, 24 C7 0.1F

32 C3 0.01F R16 2K VR1 1N963 12V R17 2K R19 8.2K R18 8.2K 34

+CAP -CAP

8 V UA 10 V LA

UC1637
15 +E/A

PWR-82341
VOA 27, 28

C8 0.1F

+ C9 TANT

17 E/A OUT R3 5K R6 10K R11 4.7M C1 0.22F 16 11 -E/A

BOUT 7

13 V UB MOTOR 15 VLB VOB 21, 22

+C/L +AIN +BW CT -AIN 2 10 8 IS 18 R13 25K -C/L -VS 5

VR2 1N963 12V 12 13

12 V SD VSSA VSSB GND 25,26 18,19 5,11,26

R7 10K

R12 47K

C2 0.0022F

R20 1K C5 0.001F R21 1K TACH R22 0.05

R23 1K

R24 1K 28V RTN

ENABLE

FIGURE 3. USING THE PWR-82341 IN A VELOCITY LOOP

2

SMART POWER H-BRIDGES CONTROL THE SPEED AND TORQUE OF DC BRUSH MOTORS

Selection of R1
(IO max). We assume the COMMAND input to be always within 10V. The current feedback signal at the CURRENT MONITOR point will be equal in magnitude and opposite in polarity to the current command signal when the circuit is regulating the load current. To achieve this objective, the current feedback circuit gain should yield a +10V signal at a load current +IO max and -10V at a load current of -IO max. The criterion for selection of the sense resistor is to get 300mV of signal at the maximum load current. We also base the power rating of this high-wattage resistor on the maximum load current. (See Table 1 for examples.)
+15V 0.01F 6 VLPI 8 10 13 15 12 VUA VLA VUB VLB VSD VOB 32 +CAP Cc 1.0F 34 -CAP GND 5, 11, 16 VCC VCC VSSA VSSB 4 V+ VOA 27, 28 +15V 0.01F

U4 PWR-82340
21, 22 30, 31 23, 24 25, 26 18, 19

COMMAND +

R12 10K

R13 22K

C1 0.047 F R14 1M

C13 0.01F 12 VLPI 14 13 VUA VLA

+15V 9 11 VLPO VZ 8 VS VOA

5

MOTOR M R1

D3 D2 1N757A 1N757A

R29 4.99k

R28 4.99k 4 AOUT

D4 1N4148

D5 1N4148

17

+15V +15V +15V C11 0.1F R19 10K R20 4.99K

7 BOUT 6 +VS

VUB U4 16 VLB PWR-82340 VOB 2 7 GND VCC 6 15 VSD VCC 3 C15 0.1F VSSA 4 VSSB 1 C16 0.1F R2

MOTOR VBUS

R3

+ C19 1500F

9 R16 1K R17 1K R18 10K R21 20K R22 4.99K

C12 0.1F

+15V

C8 10F

-BIN 1 +VTH 3 11

VBUS RTN

R26 4.99K

GND C9 10F -15V

ENABLE

-15V

R11 10K

R10 2 - 7 100 6 U5 + 4 3 C10 0.1F

U1 UC1637
-VTH

GND 18 C17 1F 10V

+AIN D1 1N4148 -VS E/A OUT 17

R9 1K

C18 1F 10V

-15V -15V

14 SHDN 2 CT 8 +BIN 10 -AIN ISET 18 R23 20K

R5 +15V

-E/A

16
R7 49.9K

C13 680pF NPO

+C/L +E/A -C/L 13 15

12 R25 1K
C7 1000pF R6 +15V

C6 47pF

C3 0.1F R8 1K

7 - 2 U2+ 3 4 -15V

C5 0.1F

R4 C2 0.1F

+15V R30 5.6M R31 50K -15V

CURRENT MONITOR

R15 100

C4 4 0.1F

7 - 2 U3+ 3

R27 1K

-15V

NOTES: 1. ALL RESISTORS ARE 1%, 1/8W UNLESS OTHERWISE NOTED. 2. ALL CAPACITORS ARE 10%, 50V UNLESS OTHERWISE NOTED.

FIGURE 4. CLOSING A CURRENT LOOP WITH THE PWR-82340 OR PWR-82341

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TABLE 1. SELECTION OF R1 EXAMPLES IO max 30A 10A 5A R1 0.01 0.03 0.06 TABLE 2. SELECTION OF R2 - R6 EXAMPLES Vbus max 150Vdc 100Vdc 80Vdc 50Vdc G1 0.0667 0.1 0.12 0.2 G2 499 333 275 167 R2, R3 75 49.9 39.2 24.9 R4, R5 4.99k 4.99k 4.75k 4.99k R6 499k 332k 274k 165k WATTS 10 5 2

Overstress to the Power MOSFETs/ Diodes could be caused by exceeding the absolute maximum voltage rating or current rating of the hybrid. The PWR82340/PWR-82341 does not have internal overvoltage or overcurrent protection. Take care to current limit power supplies and to make sure the bus voltage doesn't "pump up" when regenerative energy from the motor transfers back through the hybrid and into the bus (during braking, for example). You could use a bus clamp or load dump circuit to prevent this.

Selecting the H-Bridge

The user will select either the PWR82340 or PWR-82341, depending on maximum bus voltage and load current requirements. Both devices can be used in either velocity loop or current loop configurations and can be operated in either two- or four-quadrant mode. DDC rates the high-power PWR-82340 at 200Vdc, 30A continuous capability, while for lowerpower applications you would use the PWR-82341, rated at 100Vdc, 5A continuous. Beside the ease of use that the PWR-82340 and PWR-82341 offer, their modular approach also offers substantial printed circuit board size and weight reduction. Military and Aerospace applications will benefit by the extremely high reliability, -55C to +125C operation, and military processing.
REFERENCES: UNITRODE: UC1637 - Data sheet Application Note: U-102 - "Switched Mode Controller for DC Motor Drive." DDC: PWR-82340, PWR-82341 - Data Sheets

Selection of R2 - R6
Base the selection of these resistor values on the gain requirement of the two amplifier stages (at U2 & U3). If G1 is the gain of the differential amplifier at U2, and G2 is the gain of the differential amplifier at U3, the overall gain G = G1 * G2 = 10V/300mV = 33.3. The gain G1 depends upon the maximum bus voltage (Vbus max is 100V, G1 = 10V/ Vbus max = 0.1. This will yield G2 = 333. (See Table 2 for examples.) This could be caused by exceeding a 3V differential between the VSS pins and GND pins on the hybrid. Even if you only instantaneously exceed the 3V limit, this will damage the gate drive circuitry. Precautions for the PWR-82340 include two (2) 1.0F caps directly across the hybrid from GND (pin 18) to VSS (pins 1 & 4). You will not require these for PWR82341 because of the lower current levels involved. Ground paths for both PWR82340 and PWR-82341 should be as short as possible and low inductance. Short heavy gauge wire, ground plane, or bus bars will make the best ground connections. If you use current sense resistor(s) in the VSS legs, make sure they are noninductive and low enough in resistance value so that peak currents don't cause a voltage drop of 3V across the resistor(s). The resistor(s) should be located within 2" of the hybrid.

Layout Considerations & User Precautions

Whether you use the PWR82340/PWR-82341 as a velocity loop or current loop it is critical to follow the proper decoupling capacitor recommendations and ground/layout precautions. Improper ground schemes or poor decoupling could result in permanent damage to the PWR82340/PWR-82341.

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