Freescale Semiconductor, Inc.

Document Number: DRM144

Design Reference Manual Rev. 0, 02/2014



2014 Freescale Semiconductor, Inc.
___________________________________________________________________
Three-Phase BLDC Sensorless Motor
Control Application
by: Petr Staszko

1 Introduction
This design reference manual describes the
software portion (hardware/chip independent) of
the 16-bit implementation of a sensorless three-
phase Brushless DC (BLDC) motor control
application. The application software provided
uses the concept of an isolated motor control
algorithm software and hardware. This software
approach enables easy porting of an application
across the other devices or hardware platforms.
The application software is divided in the
following parts:
BLDC motor control algorithm process
input variables to output variables and
control flags.
Concrete hardware and microprocessor
serves as a bridge between hardware
peripheral modules and BLDC motor
control software algorithm.
This design reference manual describes the
hardware independent BLDC motor control
algorithm part of code only. It does not cover
individual implementation to respective device.
This DRM is supplemented by AN4862: Three-
Phase BLDC Sensorless Control Using the
MKV10x application note, describing
implementation of hardware dependent part of
code to the concrete devices.

Contents
1 Introduction ......................................................1
2 Control theory basics ........................................2
2.1 Brushless DC motor (BLDC motor) .........2
2.2 Digital control of BLDC motor ................3
2.3 Sensorless BLDC motor control ...............4
3 Application concept ..........................................6
3.1 System concept .........................................6
3.2 BLDC motor control .................................7
4 Software design ................................................9
4.1 Application software main process ...........9
4.2 I/O values processing ..............................10
5 Application details ..........................................12
5.1 Application state machine function ........12
5.2 Slow control loop ISR ............................17
5.3 Fast control loop ISR ..............................20
5.4 Time event ISR .......................................23
6 Acronyms and abbreviations ..........................28
7 References ......................................................29
8 Revision history ..............................................29


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The BLDC motor control algorithm is a speed closed-loop motor control algorithm using a Back-EMF
voltage integration method for a sensorless motor control. It serves as an example of a BLDC motor
control design. It is focused on a simple and easy to understand control approach to BLDC.
This reference manual includes a basic BLDC motor theory, system concept, and software design
description.
The control algorithm includes:
rotor alignment
open startup
sensorless position detection using Back-EMF voltage integration method
speed closed-loop
current/torque limitation
fault protection
2 Control theory basics
2.1 Brushless DC motor (BLDC motor)
The brushless DC (BLDC) motor is a rotating electric machine where the stator is a classical three-phase
stator similar to an induction motor and the rotor has surface-mounted permanent magnets (see Figure
1). The motor can have more than one pole pair per phase (On the picture can be seen motor with 2 pole
pairs per phase). The number of pole pairs per phase defines the ratio between the electrical revolution
and the mechanical revolution.

Figure 1. BLDC motor cross section


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2.2 Digital control of BLDC motor
The BLDC motor is driven by rectangular voltage strokes coupled with the given rotor position (see
Figure 2). The generated stator flux interacts with the rotor flux, which is generated by a rotor magnet,
defines the torque and thus the speed of the motor. The voltage strokes must be properly applied to the
two phases of the three-phase winding system so that the angle between the stator flux and the rotor flux
is kept close to 90, to get the maximum generated torque. Due to this fact, the motor requires electronic
control based on actual rotor angle position for proper operation.

Figure 2. Voltage strokes applied to the three-phase BLDC motor
For the common three-phase BLDC motor, a standard three-phase power stage is used, as illustrated in
Figure 3. The power stage utilizes six power transistors.

Figure 3. Three-phase BLDC power stage
The three-phase power stage energizes two motor phases concurrently and the third phase is unpowered
(see Figure 2). Thus, we get six possible voltage vectors that are applied to the BLDC motor using a
PWM switching signals. The unpowered phase can be used for rotor position evaluation in sensorless
motor control. The most common BLDC control topology uses the power stage with a constant power
source DC voltage. Therefore, the three-phase average voltage amplitude is controlled by a PWM duty
cycle.

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2.3 Sensorless BLDC motor control
2.3.1 BLDC motor Back-EMF voltage shape
The Back-EMF sensing technique is based on the fact that only two phases of a Brushless DC motor are
energized at a time. The third phase is a disconnected phase that can be used to sense the Back-EMF
voltage.
The Figure 4 shows branch and motor phase winding voltages during a 0-360 electrical interval. The
yellow interval (4) means a conduction interval of a phase. During this time period, current flows
through the winding, and Back-EMF voltage is impossible to measure. Cyan lines (3) determine the time
period when the Back-EMF voltage can be sensed as phase is unpowered. Gray lines (5) show the
transient pulse measured on the phase voltages right after the commutation event, which is produced by
the current recirculation when the fly-back diodes are conducting. Green lines (6) determine the time
period before the zero-cross event, the red line (7) shows the time after zero-cross event, in this period
the Back-EMF voltage is integrated, and at the end of the red interval, the integrated value of the Back-
EMF voltage reaches the Back-EMF threshold value, and this is the signal to perform a commutation.

Figure 4. Single phase voltage waveform
For more detailed information about BEMF sensing, see References.
2.3.2 Back-EMF voltage integration method
One of the sensorless BLDC motor control methods is Back-EMF voltage integration. It is based on
simple principle, the integrated value (triangle area) of the non-fed phases Back-EMF voltage after the
zero cross is approximately the same at all speeds (S1 S2 S3), as shown in Figure 5.

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Figure 5. BEMF integration method
The integration starts when the non-fed phases Back-EMF voltage crosses the zero value. Finding of
the exact time of zero-cross point is not very important as the Back-EMF voltage around the zero cross
is relatively low, integration of these low voltage values around the zero-cross has small effect to the
final integrated value. Commutation is performed when the integrated value reaches a predefined
threshold value. If a flux weakening operation is required, current advance can be achieved by
decreasing the threshold value.
In comparison to the standard sensorless technique based on BEMF zero-cross findings, the integration
approach is less sensitive to switching noise and offset voltage problems (resistance precisions, noise,
and so on). This brings more precise control in low speeds of motor. On the other hand, integration
approach is less effective in very high speeds of motor (with only few PWM periods per commutation
period), in this case the sensorless technique based on the BEMF zero-cross findings, with simple ADC
samples interpolation implemented in, demonstrates more precise motor control.
2.3.3 Back-EMF voltage sensing limitations
Accuracy of the sensorless BLDC motor control algorithm based on the Back-EMF voltage sensing is
mostly limited by the precision of measured Back-EMF voltage on non-fed motors phase. For example,
ADC accuracy, precision of phase voltage sensing circuitry, signal noise and distortion caused by the
power switching modules, all these effects need to be taken on mind. Noise generated by power
switching modules can be eliminated by correct setting of measurement event to be far away from
switching edges (PWM to ADC synchronization). There still exists limitation that cannot be eliminated,
named a decay period or freewheeling period. As soon as the phase is disconnected from the power by
commutation event, there is still current flowing through the freewheeling diode. The conduction
freewheeling diode connects the released phase to either a positive or a negative DC bus voltage. The
conduction time depends on the momentary load of the motor. In some circumstances, the conduction
time is so long that it doesnt allow for detection of Back-EMF voltage, as represented in Figure 6.

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Figure 6. BEMF decay period
In the sensorless BLDC motor control, the period after the Back-EMF voltage crosses zero is important..
If decay period is too long, then it is difficult to control motor with sensorless algorithm based on Back-
EMF technique. It is also important to differentiate Back-EMF voltage generated by the motor and phase
voltage tied to positive or negative DC bus voltage during the decay period. For this purpose, application
uses some blank period after commutation, named T
OFF
period parameter, and during this T
OFF
period
the Back-EMF voltage is not sensed and used for sensorless control. T
OFF
period is calculated as
proportional value to the previous commutation period using uw16PeriodToff parameter (for example,
0.25 means 25%). Value of this parameter should reflect the motor, load, and dynamical application
parameters.
3 Application concept
3.1 System concept
This application is developed with a focus on easy porting of software across the devices or platforms.
For this reason, the application software is divided into two separate parts of code:
Hardware dependent code (dependent on the hardware boards used and the MCU devices
peripheral modules). Includes CPU and peripheral modules initialization, I/O control drivers, and
interrupt service routines handling.
Hardware independent code (pure BLDC motor control application)


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Figure 7. System concept overview

An overview of the system concept of application is shown in Figure 7. Input and output variables and
output control flags are used as a bridge between the hardware specific part of code and motor control
algorithm. Most of the application input and output variables are stored in a fractional number
representation (in range from -1 to 1), scaling of these variable from/to the real values is calculated in
drivers (hardware related part of code).
3.2 BLDC motor control
Sensorless BLDC motor control method based on Back-EMF voltage needs measurable value of Back-
EMF voltage. This voltage is proportional to the actual rotor speed, thus it is not measurable in zero and
very low speeds. Therefore, in order to start and run the BLDC motor, the control algorithm has to go
through the following states:
Alignment: initial rotor position setting
Startup: forced commutations in open-loop mode
Run: close-loop control with BEMF acquisition

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Figure 8 shows the timing of individual BLDC motor control states.

Figure 8. BLDC motor control states
3.2.1 Alignment
As discussed in the earlier sections, the main task for sensorless control of a BLDC motor is position
estimation. Before starting the motor, however, the rotor position is not known. The aim of the
alignment state is to align the rotor to a known position. This known position enables starting the
rotation of the shaft in the desired direction and generating the maximal torque during startup. During
the alignment state, all three phases are powered in order to get the required rotor position alignment
vector. Phase A and Phase B are powered with the positive voltage and Phase C is powered with
negative voltage. The alignment time depends on the mechanical constant of the motor, including load,
and also on the applied motor current. In this state, the motor current (torque) is controlled by the PI
controller.
3.2.2 Startup
In the startup state, the motor commutations are controlled in an open-loop mode without any rotor
position feedback. The open-loop start is required only until the shaft speed is high enough
(approximately 3-10% of nominal motor speed) to produce an identifiable Back-EMF voltage. The
open-loop commutation periods are calculated based on required startup acceleration parameter and
number of startup commutations is predefined constant.
3.2.3 Run
The block diagram of run state is represented in Figure 9. It includes the BEMF acquisition with Back-
EMF integration to control the commutations. The motor speed is based on commutation time periods.
time
s
p
e
e
d
Desired
Speed
Alignment
Period
Start speed in
sensorless close
loop
Run Open Loop Start
Real speed
Open Loop:
Commutation time
calculated base on
acceleration equation
Alignment
Closed Loop:
Commutation time
calculated using Back-
EMF voltage integration
Start-up,
forced open loop
commutations
Close loop,
commutations based on
Back-EMF voltage processing
Required speed

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Speed PI controller process the difference between the demanded and estimated speeds. The output of
the speed PI controller is proportional to the voltage to be applied to the BLDC motor. The motor
current is measured and filtered in fast loop ISR and is used as feedback into the current controller. The
output of the current PI controller limits the output of the speed PI controller. The limitation of speed PI
controller output protects the motor current from exceeding maximal allowed motor current.

Figure 9. Speed control with current limitation
4 Software design
This section provides the overview of application architecture. In addition, it explains the bridge
between hardware independent and hardware dependent portions of code.
4.1 Application software main process
The whole BLDC motor control application is designed to run in the Interrupt Service Routines only. In
the main routine, there is only initialization of the microcontroller, application initialization, and an
endless loop with a FreeMASTER poll function to control and monitor the application. Application uses
three interrupts with different timing needs:
Fast Control loop ISR: executed at every PWM period
Slow Control loop ISR: executed with 1 ms period
Time Event ISR: executed according to the current application needs
The application data flow diagram with the main processes is shown in Figure 10. The interrupt service
routines are described in detail in the Application details section.
3-phase
Inverter
3-phase
BLDC
Motor
Measured
Values
Ramp
PI
Required
DC Bus
Current Limit
Required
Speed
+
+
Commutation
Control
-
-
Position
Recognition &
Revolution
Period
1/T
Volt age
L
i
m
i
t
Act ual
Speed
Act ual
DC Bus
Current
PI

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Figure 10. Application main process overview

Fast control loop ISR and time event ISR uses the same interrupt priority level; Slow control loop ISR
uses the lower priority level then previous two ISRs. Application State machine function is executed in
Fast and Time event interrupt service routines.
4.2 I/O values processing
This application uses the concept of a separate MCU specific part of code and hardware independent
BLDC motor control algorithm. The hardware related code reads the input values from the peripheral
modules (timer counter, ADC result, and others), scales them to the fractional number representation if
needed and stores as the input variables; these input variables are then processed in the hardware
independent BLDC motor control algorithm part of software. Similarly, the BLDC algorithm output
variables are processed and updated into the respective peripheral modules in hardware related code. If
there is a need to update output hardware parameter the corresponding request flag is set in the variable
uw16HwUpdateRequests during the application control algorithm execution. Function
UpdateBldcHwModules() is used to check the status of request flags and perform the appropriate
hardware modules update.
The following figure illustrates the overview of application I/O data flow:
main()
(background loop)
Peripherals initialization
Application initialization
FreeMASTER poll
Endless loop
Fast control loop ISR
(every PWM cycle)
Slow control loop ISR
(1 ms period)
Time event ISR
(predefined period)

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Figure 11. Application input/output data flow overview
4.2.1 Input application values
Input application variables are updated at the beginning of respective interrupt service routines:
uw16TimeCurrent actual time value. If timer is used for timing purpose, actual timer counter
register value is stored in this variable.
uw16TimeCurrentEvent time of last Time Event. If timer is used for timing purpose, timer
value register is stored in this variable.
f16DcBusCurrent DC bus current value in fractional number representation is stored in this 16-
bit variable. -1 means the maximal negative DC Bus current; +1 means maximal positive DC
Bus current.
f16DcBusCurrentOffset DC bus current offset value in fractional number representation is
stored in this 16-bit variable. Value is measured during the calibration state after the application
initialization.
f16DcbVoltage DC bus voltage value in fractional number representation is stored in this 16-bit
variable. 0 means 0 Volts, +1 means maximal measurable DC bus voltage.
f16PhaseVoltage phase voltage value in fractional number representation is stored in this 16-
bit variable. 0 means 0 Volts, +1 means maximal measurable DC bus voltage.
Analog Module PWM Module
Dri ver S/W
H/W & device specific S/W part
Trigger Unit
Dri ver S/W
Device independent S/W part
GPIO,
Ti mer,
Dri ver S/W
Sensorless BLDC motor control algorithm
Anal og
Measurements
Commutati on vector Ti mer val ues PWM
duty cycl e
I
/
O

V
a
r
i
a
b
l
e
s

&

C
o
n
t
r
o
l

F
l
a
g
s
GPIO,
uw16TimeCurrent
uw16TimeCurrentEvent
UPDATE_BRAKE_RESISTOR_REQ UPDATE_PWM_DISABLE_REQ
UPDATE_PWM_CONFIG_REQ
w16CmtSector
UPDATE_PWM_ALIGNMENT_REQ
UPDATE_DUTYCYCLE_REQ
f16DutyCycl e
UPDATE_TIME_EVENT_REQ
uw16TimeNextEvent
f16DcBusCurrent
f16PhaseVoltage
f16DcbVoltage
f16PhaseBemf

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f16PhaseBemf calculated Back-EMF voltage value in fractional number representation is
stored in this 16-bit variable. The following equation is used to calculate the value
(f16DcbVoltage / 2 is considered as a middle point of the motor windings):
f16PhaseBemf = f16PhaseVoltage
f16DcbVoltage
2

4.2.2 Output application values and flags
There can be pending request for hardware output update after the execution of BLDC motor control
algorithm. For this purpose UpdateBldcHwModules() function is executed. This function checks all the
request flags stored in uw16HwUpdateRequests variable and do the appropriate action based on
hardware configuration:
UPDATE_TIME_EVENT_REQ request to set new time of Time Event. In variable
uw16TimeNextEvent there is stored new time to be set. If timer is used for timing purpose, timer
value register is updated with the value of uw16TimeNextEvent.
UPDATE_PWM_DISABLE_REQ request to disable all PWM outputs. Powerstage outputs have to
be switched off.
UPDATE_DUTYCYCLE_REQ request to update duty cycle generated with PWM module. In
variable f16DutyCycle there is stored new value of duty cycle in the fractional number
representation. Fractional number value in range <-1; +1) is then processed and scaled in
appropriate PWM driver function to fit the actual PWM module configuration.
UPDATE_PWM_CONFIG_REQ request to update PWM outputs to set the new commutation
vector stored in variable w16CmtSector. Integer value in w16CmtSector is in range from 0 to 5.
UPDATE_PWM_ALIGNMENT_REQ request to apply alignment vector on the PWM outputs.
Alignment vector can be applied using special case of PWM module configuration.
UPDATE_BRAKE_RESISTOR_ON_REQ if this bit is set then output MOSFET for brake resistor
control is turned on; if it is cleared the output MOSFET for brake resistor control is turned off.
5 Application details
This chapter describes the detail use of application state machine and its states, slow and fast control
loop interrupt service routines, time event ISR, and its respective functionality based on actual state of
state machine.
5.1 Application state machine function
Global application state and BLDC motor state are controlled using two state machine functions:
Main application state machine
Motors substate machine
5.1.1 Main application state machine
Main application state machine function globally controls the whole application. It serves as a global
application switch including the fault state processing.

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It consists of four state machine functions and seven transition functions between the states. State
functions are as follows:
Fault
Init
Stop
Run
Following are the transition functions between the states:
Init to Stop
Stop to Run
Run to Stop
Fault to Init
Init to Fault
Stop to Fault
Run to Fault
After a reset an Init state function is executed. After successful application initialization execution
continues to the Stop and then to Run state. In normal operation (if any fault is not detected), application
operates in Stop and Run states only according to the main application switch value (variable
SwitchAppOnOff ). In Run state the respective motors substate machine is called. If any fault is detected
during the operation application enters the Fault state, the flow of main application state machine
diagram is represented in Figure 12.

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Figure 12. Application state machine diagram
5.1.1.1 Init state
Application enters Init state from a reset or Fault state. In this state all the variables are loaded with the
default values, including PI regulators, Speed Ramp, and Filter parameters. After that application
switches to the Stop state using TransInitStop() transition function.
5.1.1.2 Stop state
Application enters Stop state from an Init state, or from the Run state. If main application switch
(SwitchAppOnOff) is nonzero then application switches to the Run state using TransStopRun() transition
function. This transition function prepares application for calibration substate, which is the first substate
entered after changing main state from Stop to Run state.
5.1.1.3 Run state
Application enters Run state from a Stop state if the main application switch (SwitchAppOnOff) is
nonzero. In Run state, motors sub state machine is called, covering all control states required by used
motor. If main application switch is set to zero then application switches to the Stop state using
TransRunStop() transient function. This transition function checks the actual motors substate, disables
PWM output generation and enters the Freewheel substate if motor is spinning, and after the freewheel
period it acknowledges system can continue to the Stop state.
INIT
FAULT
RUN
STOP
RESET
SM_CTRL_INIT_DONE
SM_CTRL_FAULT
SM_CTRL_FAULT
SM_CTRL_START
SM_CTRL_STOP
SM_CTRL_FAULT_CLEAR
Transition
Init ->Stop
Transition
Stop ->Run
SM_CTRL_RUN_ACK
Transition
Run ->Stop
SM_CTRL_STOP_ACK
Transition
Run ->Fault
SM_CTRL_FAULT
Transition
Stop ->Fault
Transition
Init ->Fault
Transition
Fault ->Init

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5.1.1.4 Fault state
Application enters Fault state when system faced a fault condition. If any fault is detected one of three
transition functions is called (TransInitStop (), TransStopFault (), and TransRunFault()). All these three
transition functions disable the global application switch (SwitchAppOnOff); on top of that
TransRunFault() transient function disables PWM output generation, disables brake resistor, and enters
the Freewheel motors substate. State machine remains in Fault state until all detected faults are cleared
by user or software. If Fault state was entered from the Run state with motor spinning, state machine
remains in Fault state at least for freewheel period (until uw16FreewheelPeriodCurrentMs variable
value becomes zero). After all faults are cleared application switches to Init state using TransFaultInit()
transient function.
5.1.2 Motors substate machine
Motors Substate Machine function controls the actual motor state. Motors substate machine function is
called in the main application state machine in Run state. If more than one motor is driven by
application, each motor uses its own application substate machine.
Substate machine consists of six states:
Calibration
Ready
Alignment
Startup
Spin
Freewheel
When main state machine enters the Run state then Calibration substate is entered as first. After
calibration, substate machine enters Ready state and remain in one of five states - Ready, Alignment,
Startup, Spin, and Freewheel according to the required speed or actual motor speed values. See
motors substate machine diagram on Figure 13.

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Figure 13. Motors substate machine diagram
5.1.2.1 Calibration state
Application enters Calibration substate state when main state machine switches from Stop state to Run
state. Calibration state is used for the zero DC Bus current offset calibration. During the calibration, DC
Bus current is measured (and accumulated to f32DcBusCurrentAcc variable) every period defined in
microseconds using CALIB_ONE_MEASURE_PERIOD_US constant; this constant should be at least
one PWM period long. Number of calibration measurements is defined with CALIB_MEASURES_CNT
constant which is stored in uw16CalibCounter variable at the beginning. After all the measurements are
done (variable uw16CalibCounter becomes zero), DC Bus current offset is calculated from accumulated
value and stored to f16DcBusCurrentOffset variable. Then Ready substate is entered.
5.1.2.2 Ready state
Application enters Ready state from Calibration, Alignment, or Freewheel state. If required speed
(f16SpeedRequired) is below the minimal allowed speed (f16SpeedMinimal) application substate
remains in Ready state. If required speed is higher application is going to be switched to Alignment
state. According to the required speed value (if positive or negative) direction of rotation
(uw16Direction) is set and is used further in commutation function. Alignment duration variable
uw16AlignmentPeriodMs is loaded with predefined constant ALIGN_DURATION. Current PI controller
output limitation parameters are configured with alignment output parameters
(CURRENT_CONTROLLER_ALIGN_LIM_HIGH, CURRENT_CONTROLLER_ALIGN_LIM_LOW)
and Alignment vector (output PWM) is being applied. Then application substate is switched to
Alignment state.
CALIB
READY
ALIGN
FREEWHEEL
SPIN
STARTUP
Stop ->Run
Alignment time
passed
Startup ok
Calibration time
elapsed
required
speed
min
speed
<
required
speed
min
speed
<
Freewheel
period
elapsed
required
speed
min
speed
>
actual
speed
min
speed
<

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5.1.2.3 Alignment state
Application enters Alignment state from Ready state. During the Alignment state, if required speed
(f16SpeedRequired) is below the minimal allowed speed (f16SpeedMinimal) application disables PWM
output and returns back to the Ready substate. After Alignment period passes (uw16AlignmentPeriodMs
becomes zero) application is going to switch to Startup state. First commutation period (defined with
STARTUP_CMT_PER constant) is set to uw16PeriodCmtNext variable, number of open-loop
commutations STARTUP_CMT_CNT is stored to uw16StartCmtCounter variable. First commutation
vector w16CmtSector is set according to the actual direction of rotation. Then application substate is
switched to Startup state.
5.1.2.4 Startup state
Application enters Startup state from Alignment state. During the Startup state, if required speed
(f16SpeedRequired) is below the minimal allowed speed (f16SpeedMinimal) application disables PWM
output and enters Freewheel substate with period stored in uw16FreewheelPeriodShortMs variable.
When all open-loop commutations were performed (uw16StartCmtCounter becomes zero) application is
going to switch to Spin state. T
OFF
period is calculated from the last commutation period
(uw16PeriodCmtNext) using fractional multiplication by constant CMT_T_OFF (which is fractional
number less than 1) and result is stored to uw16PeriodToff variable. Last six commutation period
variables uw16PeriodCmt [x] are loaded with current commutation period uw16PeriodCmtNext. Current
PI controller is configured for Spin parameters and speed ramp function is synchronized to the actual
motor speed (target startup speed N_START_TRH). Then application substate is switched to Spin state.
5.1.2.5 Spin state
Application enters Spin state from Startup state. Application remains in Spin state until the actual motor
speed is higher than minimal allowed speed. This check is done in Slow Control Loop ISR where actual
motor speed is evaluated. If motor speed is below minimal speed application substate is switched to
Freewheel state.
5.1.2.6 Freewheel state
Application enters Freewheel state from Spin or Startup state. Remaining Freewheel period is defined in
uw16FreewheelPeriodCurrentMs variable and when it is zero application substate is switched to Ready
state.
5.2 Slow control loop ISR
Slow control loop ISR is executed at every 1 ms and is used for speed and torque evaluation and control.
Slow control loop ISR uses lower priority level in comparison with other ISRs used in the application,
therefore, it can be used for the functions that consumes more time to run, for example,
MC33927_readStatus()function can be used to read actual status of power stage driver over SPI.
Overview of slow control loop ISR is represented in Figure 14.

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Figure 14. Slow control loop ISR
5.2.1 Slow control loop function
In the slow control loop ISR there can be any part of code that is touching the hardware (in our case it is
function to read power stage status), and there is a slow control loop function which is hardware
independent. This function is hardware independent; it uses only the input and output variables and flags
to communicate with the outer world. The detailed diagram of slow control loop function is represented
in Figure 15. This function is only used in Spin and Alignment states.
Read power stage status
(MC33937 over SPI)
Slow control loop ISR
(1 ms period)
Return
Slow control loop function

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Figure 15. Slow control loop function
5.2.1.1 Spin state
In Spin state, actual motor speed (f16SpeedMeasured) is calculated using the last six commutation
periods (uw16PeriodCmt[n]). Library GFLIB_DivSat function is used for fractional division. The result
cannot overflow because of the saturation feature used in this function. In case, the actual speed is lower
than minimal allowed speed (f16SpeedMinimal), then the application enters the Freewheel state. The
speed ramp output (f16SpeedRampOutput) is calculated using the library GFLIB_Ramp function. Note
that 32-bit implementation of ramp function is used to provide the better speed step resolution in 1 ms
call period, therefore 32-bit to 16-bit and opposite library conversion functions are used
Slow control loop
Return
Calculate actual speed
StateRun =
SPIN?
StateRun =
ALIGN?
actual speed <
minimal speed
Disable PWM
StateRun =FREEWHEEL
Return
Speed Ramp
Speed PI Controller
Current PI Controller
CurrentPiOutput >
SpeedPiOutput
DutyCycle =SpeedPiOutput DutyCycle =CurrentPiOutput
Current PI Controller
DutyCycle =CurrentPiOutput
+
-
+
-
+
-
+
-
Current
limiting
Speed
control

Three-Phase BLDC Sensorless Motor Control Application, Rev. 0, 02/2014
20 Freescale Semiconductor, Inc.
(MLIB_ConvertPU_F32F16 and MLIB_ConvertPU_F16F32). According to the actual direction of
rotation the sign of f16SpeedMeasured variable is set and input to the speed PI controller
(f16SpeedPiErr) is calculated. Then speed PI controller and current PI controller are calculated using
library GFLIB_ControllerPIpAW function. If speed PI controller output is higher than the output of
current PI controller then current limiting is applied to the output, it means the current PI controller
output is used instead of the speed PI controller output. This will reduce the speed of motor but the
phase current do not exceeds the limit value in f16DcBusCurrentLimit variable.
5.2.1.2 Alignment state
In Alignment state, slow control loop function controls the phase (which is equal to DC Bus) current to
required alignment current value stored in f16DcBusCurrentAlign variable. From this value and the
actual DC Bus current value (f16DcBusCurrentNoFiltered) the input to the current PI controller is
calculated; then the output duty cycle (f16DutyCycle) is calculated using PI controller.
5.3 Fast control loop ISR
Fast control loop ISR is executed at every PWM cycle and is used for a rotor position recognition and
commutation. Fast control loop ISR uses the same priority level as of time event ISR (so it should not be
interrupted by time event ISR) but it is higher than the slow control loop ISR. Overview of fast control
loop ISR is represented in the following figure:

Figure 16. Fast control loop ISR
Inside the fast control loop ISR there is a portion of the code that is connecting with the hardware, and
hardware independent fast control loop function. At the beginning of ISR the actual time (timer counter
value) is stored in the uw16TimeCurrent variable. Then results of analog measurements are scaled in 16-
bit fractional number representation and stored to the following variables:
Read and scale:
DC Bus voltage
DC Bus current
phase voltage
Read actual time
Fast control loop ISR
(every PWM cycle)
Filter DC Bus current
Calculate back-EMF voltage
Call fast control Loop
function
Configure next analogue
measurements
Check Fault states
Call State machine function
Update peripheral modules
setting based on requests
Return

Three-Phase BLDC Sensorless Motor Control Application, Rev. 0, 02/2014
Freescale Semiconductor, Inc. 21

f16DcBusCurrent
f16PhaseVoltage
f16DcbVoltage
DC Bus current is filtered using library GDFLIB_FilterMA function (Moving average filter) and stored
in f16DcBusCurrent variable. Phase Back-EMF voltage f16PhaseBemf is calculated using phase voltage
and DC Bus voltage values. Then fast control loop function is called (is described in Fast control loop
function). Then the analog measurement configuration for next PWM cycle module is set according to
the updated BLDC sector. Faults are tested in ReadSwFaults()function, this function checks the
measured analog values for DC bus overcurrent, overvoltage, and undervoltage limits; respective fault is
stored in the global fault mintM1_Fault variable. Then application state machine SM_StateMachine()
function , is called (for more details, see Main application state machine). At the end, hardware modules
are updated in UpdateBldcHwModules() function (for more details, see I/O values processing).
5.3.1 Fast control loop function
The main function in fast control loop ISR is fast control loop function. This function is hardware
independent; it uses only input and output variables and flags to communicate with the outer world.
Detailed diagram of a slow control loop function is shown in Figure 17. This function is used in Spin
state only.

Three-Phase BLDC Sensorless Motor Control Application, Rev. 0, 02/2014
22 Freescale Semiconductor, Inc.

Figure 17. Fast control loop function
In the beginning of a slow control loop function the actual motors substate is tested; if actual state is
different than Spin state then the function exits. Brake resistor is updated according to the actual DC bus
voltage stored in f16DcbVoltage variable and limit value defined with U_DCB_TRIP constant. T
OFF

period is compared with a period of last commutation, which is calculated from actual time
(uw16TimeCurrent) and time of last commutation (uw16TimeOfCommutation). Exit if the T
OFF
period
was not elapsed. Then according to the actual BLDC sector applied and direction of rotation, the Back-
EMV voltage is inverted in f16PhaseBemf variable; from this point the Back-EMF voltage in
f16PhaseBemf is always raising from negative values to positive. Afterwards, the simple zero-cross
detection condition is used and the Back-EMF voltage is integrated to f32IntegralBemfSumvariable if it
-
+
Fast control loop
Return
StateRun =
SPIN?
-
Return
Process Brake resistor
+
T
OFF
period
elapsed?
Return
+
-
Falling
back-EMF?
invert back-EMF voltage
+
-
back-EMF
>0
Back-EMF voltage
Integration
+
-
back-EMF
integral >
threshold
Disable PWM
StateRun =FREEWHEEL
+
-
CMT period
<minimal
Return
Commutation
- Save CMT time, periods
- Perform commutation
- Calculate T
OFF
period
- Set next timed safety
commutation

Three-Phase BLDC Sensorless Motor Control Application, Rev. 0, 02/2014
Freescale Semiconductor, Inc. 23

is positive (after the Back-EMF zero-cross). If integrated value of Back-EMF voltage, stored in
f32IntegralBemfSumvariable, is greater than the threshold value in f32IntegralBemfThreshold then it is
time to perform a commutation. Actual commutation period is calculated using the actual time stored in
uw16TimeCurrent and previous commutation time in uw16TimeOfCommutation, is compared to the half
of the minimal commutation period defined with CMT_PER_MIN constant; this constant value is
calculated from the maximal motors speed, number of motors pole-pairs, and timer frequency.
Application enters the Freewheel state in case the commutation period is going to be too short. Actual
commutation time variable uw16TimeOfCommutation is updated, commutation period variable is
uw16PeriodCmt[n] is calculated from the actual and previous commutation times and commutation is
performed calling BldcCommutation() function. BldcCommutation() function simply increases or
decreases the actual commutation sector stored in w16CmtSector variable according to the actual
direction of rotation in uw16Direction; PWM output is then updated in function
UpdateBldcHwModules() (for more details, see I/O values processing). Then new value of T
OFF
period is
calculated from the last commutation period using fractional multiplication by constant CMT_T_OFF
(which is a fractional number less than 1) and result is stored to uw16PeriodToff variable. Integrated
value of Back-EMF voltage (f32IntegralBemfSum) is cleared, and it is marked that application just
commutated using sensorless algorithm - variable uw16CommutatedSensorless is set to one; this is
useful for case the Time event ISR is going to be executed and performing the safety commutation
(will be described later). Safety commutation (uw16TimeNextEvent) is set to double of last commutation
period.
5.4 Time event ISR
Time event ISR is used to fulfill the following purposes:
Individual application states timing
Open-loop commutations timing in Startup state
Safety commutation in Spin state
If sensorless motor control algorithm fails in rotor position recognition then the time event ISR protects
motor from overcurrent. Overview of time event ISR is represented in Figure 18.

Three-Phase BLDC Sensorless Motor Control Application, Rev. 0, 02/2014
24 Freescale Semiconductor, Inc.

Figure 18. Time event ISR
At the beginning of time event ISR, the actual time and event time are stored in uw16TimeCurrent and
uw16TimeCurrentEvent variables. The value of uw16TimeCurrent is saved by the ISR software at the
beginning of this ISR and the value of uw16TimeCurrentEvent variable is saved when the ISR is
originated by MCU hardware. For precise timing uw16TimeCurrentEvent variable is considered as the
right time value. After that the Time event function is called (will be described in next chapter). Then
application state machine function SM_StateMachine() is called (for more details, see Main application
state machine). At the end hardware modules are updated in UpdateBldcHwModules() function (for
more details, see I/O values processing).
5.4.1 Time event function
Time event function has a different functionality based on the actual motors substate machine state. It
provides simple timing to Alignment, Calibration, and Frewheel states. In Startup state, the time event
function is used for the open-loop commutations timing, where each following commutation period is
calculated from the previous commutation period. In Spin state, if a sensorless motor control algorithm
cannot recognize rotors position (for any reason) then the time event function serves for the safety
commutations. The detailed diagram of time event function is represented in Figure 19 and Figure 20.

Read actual time
Time event ISR
(predefined period)
Time event function
Update peripheral modules
setting based on requests
Call State machine function
Return

Three-Phase BLDC Sensorless Motor Control Application, Rev. 0, 02/2014
Freescale Semiconductor, Inc. 25


Figure 19. Time event function (Spin and Startup states)

-
+
+
-
Time event function
StateRun =
SPIN?
-
StateRun =
STARTUP?
Perform Commutation
Decrement Start CMT
counter
+
-
Start CMT
counter >0?
Set next safety commutation
period
Set next Start commutation
period
Return
Still start-up
+
-
Commutated
sensorless?
Return
+
CmtErrorCnt
<max
Disable PWM
StateRun =FREEWHEEL
Return
Increment CmtErrorCnt
Commutation
- Save CMT time, periods
- Perform commutation
- Calculate T
OFF
period
- Set next timed safety
commutation
Return
continue

Three-Phase BLDC Sensorless Motor Control Application, Rev. 0, 02/2014
26 Freescale Semiconductor, Inc.
5.4.1.1 Spin state
In Spin state, if a sensorless BLDC motor control algorithm is working fine, the Time event ISR will
never be executed, because the commutations are performed in a fast control loop function executed in
fast control loop ISR. But in case the sensorless BLDC motor control algorithm cannot recognize rotors
position correctly, the time event ISR is used for the safety commutation of the motor. Period to the
next (safety) commutation is set to double of last commutation period. In case of normal operation the
sensorless algorithm should recognize a correct rotor's position and commutate normally within this
period (before this safety commutation is executed), in this case the safety commutation is canceled and
again postponed to double of last commutation period. In case the sensorless algorithm cannot recognize
rotors position correctly, the time event ISR is used for the safety commutation of the motor. Safety
commutations limit the overcurrents in a motor if sensorless algorithm fails. At the beginning of time
event function uw16CommutatedSensorless variable is checked, if it is set then the commutation was
performed in fast control loop just before the time event ISR was originated, in that case function exits
because the sensorless motor control algorithm works still fine, even it was commutated just at the end
of the window established for the sensorless commutations. Otherwise the safety commutation is going
to be performed. Every time the safety commutation is performed uw16CmtErrorCnt variable is
increased by 3, conversely when motor is commutated in fast control loop using sensorless algorithm
uw16CmtErrorCnt is decreased. If uw16CmtErrorCnt is higher than maximal allowed number of
commutation fails application enters Freewheel start. If number of errors is less than limit then
application continues same way as in fast control loop. Actual commutation time variable
uw16TimeOfCommutation is updated, commutation period variable is uw16PeriodCmt[n] is calculated
from the actual and previous commutation times and commutation is performed calling
BldcCommutation() function. New value of T
OFF
period uw16PeriodToff is calculated from the last
commutation period. Integrated value of Back-EMF voltage (f32IntegralBemfSum) is cleared and next
safety commutation (uw16TimeNextEvent) is set to double of last commutation period.
5.4.1.2 Startup state
In Startup state the time event function is used for the open-loop commutations timing. The
commutation is performed at the beginning of the time event function in Startup state. Then number of
open-loop commutations is decreased and checked (uw16StartCmtCounter). If it is still higher than zero
the next commutation period is calculated from the previous commutation period multiplied with an
acceleration coefficient, f16McatStartCmtAcceleration. Acceleration coefficient is a fractional constant
number (number a little bit less than 1), and defines the ratio between lengths of two consequential
commutation periods. MCLIB_MUL library function is used for fractional multiplication. Acceleration
coefficient is calculated from the first commutation period after an alignment and the target Startup
speed. When all Startup (open-loop) commutations were performed, application will switch to the Spin
state (sensorless close-loop motor control); period to the next (safety) commutation is set to double of
last Startup commutation period.

Three-Phase BLDC Sensorless Motor Control Application, Rev. 0, 02/2014
Freescale Semiconductor, Inc. 27


Figure 20. Time event function (Alignment, Calibration, and Freewheel states)
+
+
-
StateRun =
ALIGN?
-
Alignment
period >0?
Decrement Alignment period
Set period to next
Time Event (1 ms)
Return
+
+
-
StateRun =
CALIB?
-
Calibration
counter >0?
Decrement Calibration counter
Accumulate DC Bus current
Set period to next
Time Event
Return
+
+
-
StateRun =
FREEWHEEL?
-
Freewheel
period >0?
Decrement Freewheel period
Set period to next
Time Event (1 ms)
Return
Return
continued

Three-Phase BLDC Sensorless Motor Control Application, Rev. 0, 02/2014
28 Freescale Semiconductor, Inc.
5.4.1.3 Alignment state
In Alignment state, the time event function is used for timing purpose. uw16AlignmentPeriodMs
variable is decreased every 1 ms down to zero. It is then tested for zero in Alignment state of motors
substate machine.
5.4.1.4 Calibration state
In Calibration state, the time event function is used for timing purpose. Variable uw16CalibCounter is
decreased every period defined by CALIB_ONE_MEASURE_PERIOD_US constant in microseconds
(this constant should be at least one PWM period long). During the calibration, DC Bus current is
measured and accumulated to f32DcBusCurrentAcc variable. After all the measurements are done
(variable uw16CalibCounter becomes zero), then the DC Bus current offset is calculated from
accumulated value and stored to f16DcBusCurrentOffset variable in Calibration state of motors substate
machine.
5.4.1.5 Freewheel state
In Freewheel state, the time event function is used for timing purpose. uw16FreewheelPeriodCurrentMs
variable is decreased every 1 ms down to zero. It is then tested for zero in Freewheel state of motors
substate machine.
6 Acronyms and abbreviations
Table 1. Acronyms
Term Meaning
ADC Analog-to-digital converter.
BEMF Back-electromotive force.
BLDC Brushless DC motor.
CPU Central processing unit.
DC Direct current.
DRM Design reference manual.
I/O
Input/output interfaces between a computer system and the external world a CPU
reads an input to sense the level of an external signal and writes to an output to
change the level of an external signal.
ISR Interrupt Service Routine.
MCU Microcontroller.
PI controller Proportional-integral controller.
PWM Pulse-width modulation.
SPI Serial peripheral interface module.

Three-Phase BLDC Sensorless Motor Control Application, Rev. 0, 02/2014
Freescale Semiconductor, Inc. 29


7 References
Following references are available on freescale.com:

1. K10 Sub-Family Reference Manual, KV10P48M75RM, by Freescale Semiconductor, Inc., 2013.

2. Set of General Math and Motor Control Functions for ARM Cortex M0+ Core, CM0MCLUG,
by Freescale Semiconductor, Inc., 2013.

3. 3-Phase BLDC Motor Sensorless Control using MC9S08AW60, DRM086, by Freescale
Semiconductor, Inc., 2005.

4. 3-Phase BLDC Motor Sensorless Control using MC9S08MP16, DRM117, by Freescale
Semiconductor, Inc., 2009.

8 Revision history
Table 2. Revision history
Revision number Date Substantial changes
0 02/2014 Initial release




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Document Number: DRM144
Rev. 0
02/2014