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Application Report

SLVA443 November 2010

High-Resolution Microstepping Driver with the


DRV8828/29/40
Jose Quiones ..................................................................................................... High-Volume Analog
ABSTRACT
This application report is provided as a supplement to the DRV8828, DRV8829, and DRV8840 product
data sheets. It details the hardware implementation of the DRV8828/29 and an MSP430F2112
microcontroller in a combination that allows a pair of dc motor drivers to drive a bipolar stepper motor in a
microstepping configuration with up to 32 degrees of resolution.

1
2
3
4
5

Contents
Introduction .................................................................................................................. 2
Full Step vs Microstep ...................................................................................................... 3
Application Block Diagram ................................................................................................. 5
Schematics ................................................................................................................... 9
PCB Layout ................................................................................................................. 13
List of Figures

Conventional Bipolar Stepper Motor Full Step Commutation ......................................................... 3

Microstep Division of a Full Step .......................................................................................... 3

Embedded Waveform Results............................................................................................. 4

Conceptual Block Diagram

Look-Up Table to GPIO Output Register Transfer

6
7
8
9
10
11
12
13

................................................................................................ 5
..................................................................... 7
Current Magnitude, Phase, and Decay Relationship ................................................................... 8
Interrupt Service Routine Flowcharts ..................................................................................... 9
MSP430 Microcontroller with JTAG Programming Port and Test Points Schematic ............................. 10
Input Power and Regulation Schematic ................................................................................ 11
DRV8828/29 Power Stage Schematic .................................................................................. 12
Top Layer Image .......................................................................................................... 13
Bottom Layer Image....................................................................................................... 13
PCB Silkscreen ............................................................................................................ 14

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Introduction

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Introduction
Bipolar stepper motor applications are often designed to be driven at full steps. However, it is well-known
that when each step is divided into multiple, smaller steps (referred to as microsteps), better motion quality
can be observed. The application of microstepping to most stepper applications allows for additional
application improvements, such as:
Better torque response
Less vibration
Less resonance incidence
Any stepper motor can be microstepped. TIs DRV8811 and DRV8821 motor controller devices allow
users to apply microstepping waveforms to bipolar stepper motors with up to 8 degrees of microstepping.
The complementary DRV8824 and DRV8825 each offer extended microstepping ranges of 16 and 32
degrees, respectively.
In Application Report SLVA416 (available for download at www.ti.com), we discussed how to interface an
MSP430F1612 microcontroller to a single DRV8812 or dual DRV8828/29/40 devices in order to obtain
additional degrees of microstepping (up to 256 degrees) and multiple waveform shapes. This configuration
is the most flexible option, and allows up to 5 A per phase, up to 4096 degrees of microstepping, and any
number of waveform shapes that we can store within the 55 kB of flash ROM.
This implementation is very flexible and advantageous for applications that require the type of flexibility
described. But what options are available if the application requires only up to 32 degrees of
microstepping and a simple sine waveform?
The DRV8828/29/40 devices each include an internal, 5-bit digital-to-analog converter (DAC). As a result,
there is no need to use advanced techniques through large and convoluted look-up tables within a
microcontroller, or to have the added expense of a rather large microcontroller unit. All we must do is to
incrementally step through the 5-bit values that generate a sine wave current control envelope, and
microstepping has been achieved.
In this report, we describe an easy-to-follow procedure to achieve a simple but robust 32 degrees of
microstepping drive with the use of a microcontroller such as the MSP430F2112, in combination with a
pair of DRV8828/29/40 devices.

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Full Step vs Microstep

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Full Step vs Microstep

2.1

The Full Step


Stepper motors are brushless motors. In other words, they lack a brush making mechanical contact with a
commutator, as housed on the typical brushed dc motor. Because of this, stepper motors must be
electronically commutated. The most common way of commutating the rotor into motion is by modulating
the magnetic field of each stator electromagnet. Figure 1 illustrates the typical method to achieve full step
commutation.
VBB

VBB
AAH

BAH

ABH

BBH

AAH

B
Bipolar

A
B

AAL

BAL

ABL

AAL
BAH

ABL

BAL
ABH

BBL

BBH

BBL

(a) Bipolar Motor and Drive

(b) Polarization Sequencing

Figure 1. Conventional Bipolar Stepper Motor Full Step Commutation


There are two stator electromagnets on any conventional bipolar stepper motor, which is why two
H-bridges are needed. For this application to work, we must have two DRV8828/29/40 devices, each
driving one of the stepper motor windings. By modulating both PHASE A and PHASE B pins to obtain a
polarization waveform such as the one shown in Figure 1, the motor will move in full steps.

2.2

The Microstep
If full steps are all that the application requires, then the configuration presented Figure 1 is the optimal
solution. However, many applications can certainly benefit from dividing full steps into smaller steps.
Figure 2 shows two full steps on the top and one way to divide each full step into eight smaller steps. It is
an industry-standard practice to use a sine waveform shape, which is why the DRV8828/29/40 internal
5-bit DAC was optimized for each corresponding combination to resemble the indicated waveform.

One Step

One Step

Eight Microsteps

Eight Microsteps

Figure 2. Microstep Division of a Full Step

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Full Step vs Microstep

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The idea behind microsteps is to make the current that flows through the winding a fraction of either the
Full On current in one direction or the Full On current in the opposite direction. This approach allows for
the rotor to be pushed/pulled in increments rather than with full force. At the same time, this technique
allows for the rotor to stop in between the positions allocated for full steps. As a result, specific positioning
obtains further resolution.
Because the DRV8828/29/40 each have the capability to regulate winding current, and that current is
directly proportional to the 5-bit combination present on the I[4:0] bits, it is possible to embed the
prospective sine waveform at the current side. Figure 3 shows the result of embedding the waveform into
the winding current.
One
Step

Phase A

1
Phase B

Internal
VREF A

2
Internal
VREF B

Current A

Current B

Figure 3. Embedded Waveform Results


With a microcontroller such as the MSP430F2112 and the use of general-purpose inputs/outputs (GPIOs),
we can drive the DRV8828/29/40 PHASE inputs in the alternating fashion we saw in Figure 1 and
Figure 2. However, the I[4:0] bits will be simultaneously driven by using 10 GPIO outputs with an
incremental or decremental counter sequence, which then superimposes a sine wave crest.
As a result, the motor windings see a full sine wave of applied current. Because the current is segmented
in smaller steps, the rotor also moves in smaller steps.

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Application Block Diagram

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Application Block Diagram


In essence, the combination illustrated in Figure 4 is similar to how a stepper with an internal indexer
(such as the DRV8811, DRV8821, DRV8824, or DRV8825) operates. A logic block samples a series of
inputs and generates respective control signals to the dual H-bridges. Typical internal indexer driver
devices represent an encased application and cannot be modified. However, by splitting the application
into a microcontroller and a driver, more flexibility is obtained.

Ix[4:0]
Five GPIOs
OUTA+
USM0

Enable

USM1

Phase

DRV8828/
8829

OUTA-

Decay

nSLEEP
STEP
VREF
DIR

MSP430F21
Ix[4:0]

Index Reset
Five GPIOs
OUTB+
Enable

Phase

Decay

DRV8828/
8829

OUTB-

nSLEEP

VREF

Enable

nSLEEP

VREF

Figure 4. Conceptual Block Diagram


In this particular application, we obtain the flexibility of driving a stepper motor with more current;
specifically, a selection of up to 3 A (DRV8828) or up to 5 A (DRV8829/40) per phase. It is very difficult for
integrated devices to provide such large currents because the FET transistors would have to be very
large. This requrement, in turn, would make the device considerably more expensive. The proposed
solution is extremely cost-effective. At the same time, it provides a very robust stepper drive
implementation.
Figure 4 shows how the MSP430F2112 drives the control signals such as PHASE, DECAY, and the Ix
bits. These signals are derived from conventional GPIOs configured as outputs.
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Application Block Diagram

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Note that the VREF analog signal is not shown here, but considered as part of this solution. The VREF
analog signal can be supplied externally or through the use of an MSP430 timer output fed through an RC
filter in order to a generate a cost-effective DAC output.
Inputs such as STEP, DIR, USMx, and IndexReset are sampled by a series of interrupt service routines
(ISRs). Whenever a respective rising or falling edge is detected, the ISR computes the next step and
generates the respective output combination.

3.1

Microcontroller Side Control Signals


There are four primary microcontroller side control signals involved in this solution:
STEP: Microcontroller timer input configured to capture and interrupt on rising edges. A transition from
low to high tells the microcontroller to issue a new step. Transitions from high to low are ignored,
although it is the users prerogative to code this change so that both transitions generate a step.
DIR: Microcontroller timer input configured to capture and interrupt on both edges. Selects the bipolar
motor direction of rotation. LO implies a counter-clockwise rotation, while HI selects a clockwise
rotation. These diections are arbitrarily chosen and can be changed according to preference.
Index Reset: Microcontroller timer input configured to capture and interrupt on a falling edge. A falling
edge on this pin clears the internal indexer. H-bridge enablement is not controlled by this feature.
USMx: Microcontroller GPIO configured to trigger an interrupt on either transitional edge. Selects the
four possible degrees of microstepping resolution. In this application note, quad step (or 4 degrees), as
well as 8, 16, and 32 degrees of microstepping were coded.

3.2

Firmware Variables
A series of variables will hold the states and the values required to generate the microstepping as detailed
in the balance of this report.
SineWave[128]: A 128-byte long look-up table containing all the information necessary to generate
magnitude, sign, and current recirculation mode to be used during the generation of the 32 degrees of
microstepping sine waveform.
MSCounter: A continuously-increasing byte that is used as an index to the SineWave[128] look-up
table.
MSDirection: A boolean value used to determine whether the motor should be rotating while following
the clockwise or counter-clockwise convention.
MSIncrement: An integer added to the MSCounter and used to move through the look-up table in
single or larger increments as denoted by the User Mode bits USMx.
32 degrees of microstepping are obtained when all the values in the logic table are used. In order to
obtain fewer degrees of microstepping, fewer corresponding values are fetched from the table. In this
form, the increment is used to select look-up table values that are one address location apart for 32
degrees of microstepping, two address locations apart for 16 degrees of microstepping, four address
locations apart for 8 degrees of microstepping, and eight address locations apart for quad stepping.
When MSIncrement is modified, as when any of the USMx bits change, the MSCounter must be
normalized to the proper increment range in order to avoid waveform deformation. For example, while
employing a quad stepping method, the look-up table values retrieved are from the address locations 0, 8,
16, 24, and so on. However, if the MSCounter is any value between 0 and 8, for example, adding
MSIncrement = 8 to the current MSCounter causes the retrieval of invalid look-up table addresses.
To normalize the MSCounter according to the selected degrees of microstepping, a mask clears the least
significant bits. For example, if quad stepping is selected, bits 0 to 2 in the MSCounter would be cleared,
while bits 0 to 1 would be cleared for 8 degrees of microstepping, and bit 0 would be cleared for 16
degrees of microstepping. There is no need to perform any normalization when 32 degrees of
microstepping are selected because all the values in the look-up table are allowed.

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Application Block Diagram

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3.3

Look-Up Table and Hardware Mapping


Although we could have used mathematical equations to generate the microstep information according to
an ever-increasing index variable, it is considerably easier to code a very simple look-up table that
contains the magnitude information, as well as the respective PHASE and DECAY states. An
ever-increasing index, or waveform pointer, is used to extract data from the look-up table that is encoded
as shown in Table 1.
Table 1. Look-Up Table
b7

b6

b5

b4

b3

b2

b1

b0

Not used

DECAY

PHASE

I4

I3

I2

I1

I0

Figure 5 shows how the hardware pinout on the microcontroller has been coded so that PORT 2 is
connected to stepper PHASE A, whereas PORT 3 is connected to stepper PHASE B. Therefore, all we
must do is to retrieve the value from the look-up table in memory and feed it to the respective Port Output
Register (PxOUT).
Not Used
b7
Byte 0
Value A

Index
32

S
Value B

b6

DECAY

b5

PHASE

b4

I4

b3

I3

b2

I2

b1

I1

b0

I0
DRV8828/29

POUT2

Not Used
b7
b6

DECAY

b5

PHASE

b4

I4

b3

I3

b2

I2

b1
Byte 127

b0
POUT3

I1
I0
DRV8828/29

Figure 5. Look-Up Table to GPIO Output Register Transfer


Because both PHASE A and PHASE B are always 90 degrees out of phase, the same table can be used
for both phases if we fetch values that are 90 degrees out of phase with each other. For this application,
we will need to code a 128-byte long table in order to store all the possible 7-bit combinations.
The look-up table is 128 steps deep; consequently, the 90 degrees out-of-phase mark is obtained by
looking 32 steps away from the present step at the table. In this case, we have chosen the index variable
(MSCounter) to always look at the PHASE A output. PHASE B is then deduced by looking at the current
index 32 look-up table space. The direction signal (DIR) determines whether we fetch the location
pointed by (index +32) or by (index 32) as this result generates PHASE B trailing PHASE A or PHASE B
leading PHASE A, respectively. For any bipolar stepper motor, this difference in angle results in the motor
rotating clockwise or counter-clockwise.

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Application Block Diagram

3.4

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Sine Wave Generation


In order to fill the look-up table with meaningful values, we must consider the waveform we want to
generate. We want to embed an ac sine wave on top of the full-step phase information. The Ix bits provide
us with information about magnitude, 32 possible values normalized to a sine waveform shape.
In order to fully form the sine wave, we must continuously increase the Ix bits from 0 to 31 and then
decrease from 31 to 0. This process repeats continuously. In Figure 6, we can observe the increasing
occurring in quadrants 1 and 3, while the decreasing takes place in quadrants 2 and 4.
Quadrant 1

Quadrant 2

Quadrant 3

Quadrant 4

Ix Increases

Ix Decreases

Ix Increases

Ix Decreases

Phase

Decay

Figure 6. Current Magnitude, Phase, and Decay Relationship


PHASE alternates once per full half sine wave generation. Therefore, we can see quadrant 1 and
quadrant 2 will have one PHASE level, while quadrant 3 and quadrant 4 will have the opposite level value.
DECAY is applied to allow for the waveform to remain truthful to its shape, regardless of motor
inductance. Recall that it is easier to charge the inductance than it is to discharge it. Consequently, when
current is growing in the inductive load (quadrants 1 and quadrant 3), we can use slow decay as a mode
to re-circulate current through the H-bridge every time it enters ITrip.
However, while in slow decay mode and as the current values start to decrease (quadrant 2 and quadrant
4), we could face a distortion caused by the fact that current is being asked to decay through a highly
resistive path. By using fast decay in these quadrants, we help the current decrease faster and follow its
true intended path.

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Schematics

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If fast decay mode results in operation that is too noisy, then mixed decay mode could be employed. For
this mode, the respective DECAY pins could be configured as inputs during the respective quadrants,
rendering them high impedance. This condition is the 3-state polarity at which the DRV8828/29/40 DECAY
inputs are signaled to re-circulate current in Mixed Decay Mode.

3.5

Interrupt Service Subroutine Flow Charts


Figure 7 portrays the ISRs to coordinate the stepping generations. ISRs are driven by transitions on the
timer inputs configured as Input Captures. The STEP input ISR is only triggered with a rising edge, while
the DIR input ISR is triggered on both rising and falling edges.
A

Sample STEP

Sample DIR

No

No
Step?

Yes
Is DIR CW?

Yes

Increment Index

Increment = -32

Increment = 32

PORT2 =
Sinewave[Index]

PORT3 =
Sinewave[Index + Increment]

Figure 7. Interrupt Service Routine Flowcharts


When the STEP input ISR is triggered, the Index MSCounter is incremented or decremented according to
whether the motor is moving clockwise or counter-clockwise. This direction is defined during the previous
transition on the DIR input.
When the DIR Input ISR is triggered, the level state of the DIR pin is sampled and the boolean variable
MSDirection is set or cleared accordingly.

Schematics
Figure 8 through Figure 10 show the schematics for the recommended design solution.

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Schematics

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V3p3
U3
1
2
3
4
5
6
7
8
9
10
11
12
13
14

TEST
0.1uF

PHASE_A
C11
USM1
DECAY_A
RST
PHASEA_I0
PHASEA_I1
PHASEA_I2
PHASEB_I0
PHASEB_I1
PHASEB_I2
PHASEB_I3

GND

TST/SBW
DVCC
P2.5
DVSS
P2.7 /XOUT
P2.6 /XIN
RST
P2.0
P2.1
P2.2
P3.0
P3.1
P3.2
P3.3

TDO
TDI
TMS
TCK
P1.3
P1.2
P1.1
P1.0
P2.4
P2.3
P3.7
P3.6
P3.5
P3.4

P1P7
P1P6
P1P5
P1P4
IndexReset
DIR
STEP
USM0
PHASEA_I4
PHASEA_I3

28
27
26
25
24
23
22
21
20
19
18
17
16
15

DECAY_B
PHASE_B
PHASEB_I4

R10
5.1K

MVREF

C15
0.01uF

MSP430F2132
V3p3
GND
J3
P1P7

JP4

1
3
5
7
9
11
13

R3 P1P6
3.3K P1P5
P1P4
RST

2
4
6
8
10
12
14

1
2
3

TEST

PWR Select

MCU RESET

JTAG

S1

GND

nSLEEP

ENABLE

DECAY_B

PHASE_B

PHASEB_I0

PHASEB_I1

PHASEB_I2

PHASEB_I3

PHASEB_I4

DECAY_A

PHASE_A

PHASEA_I0

PHASEA_I1

PHASEA_I2

PHASEA_I3

PHASEA_I4

TP3

TP4

TP5

TP6

TP7

TP8

TP9

TP10

TP11

TP12

TP13

TP14

TP15

TP16

TP17

TP18

GND

PHASEA_I4

PHASEA_I3

PHASEA_I2

PHASEA_I1

PHASEA_I0

PHASE_A

DECAY_A

PHASEB_I4

PHASEB_I3

PHASEB_I2

PHASEB_I1

PHASEB_I0

PHASE_B

DECAY_B

ENABLE

nSLEEP

Figure 8. MSP430 Microcontroller with JTAG Programming Port and Test Points Schematic

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Schematics

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VM

J4

R4 3.3K
V3p3
USM1

USM1

D1

C12

C13

0.1uF

100uF

VM

VM

1
2

JP1
V3p3
J5

USM0

USM0

nSLEEP

VM
TP1

V3p3

nSLEEP
3

JP3

Header 10

VM

U4

1
1

V3p3

R5
C14

R6
3.3K

61.9K

2
3
4

10 uF
IndexReset

R7
39K

IN

FB

NC

NC

NC

GND

EN

8
7
6
5

TPS79801

GND
TP2
1

S2
Index Reset

OUT

GND

JP2

ENABLE
STEP
DIR
IndexReset
USM1
USM0
nSLEEP
XVREF

1
2
3
4
5
6
7
8
9
10

GND

CPGCOM Connector
GND

J6

XVREF
ENABLE
IndexReset
USM0 SLEEP

GVDD
1
SDA
3
SCLK OSI
5
MISO
7
ADC0
9
ADC2 DC3
11
DAC0 AC1
13
TMR0 MR1
15
TMR2 MR3
17
GPIO0 PIO1
19
GPIO2 PIO3
21
GPIO4 PIO5
23
GPIO6 PIO7
25
GVCC
27
GVCC
29

2
4
6
8
10
12
14
16
18
20
22
24
26
28
30

GND
SCL
M
SS
ADC1
A
D
T
T
G
G
G
G
GND
GND

STEP
DIR
USM1
n

Header 15X2
GND

Figure 9. Input Power and Regulation Schematic

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Schematics

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V3P3OUT
VM

V3p3

0.1uF

0.01uF

C2
AOUT+
ISENA
AOUTAOUTISENA
AOUT+

R8
0.3

VREF

C5

CP1
CP2
VCP
VMA
OUT1
ISENA
OUT2
OUT2
ISENB
OUT1
VMB
AVREF
BVREF
GND

GND
I4
I3
I2
I1
I0
NC
EN
PH
DECAY
nFAULT
nSLEEP
nRESET
V3P3OUT

28
27
26
25
24
23
22
21
20
19
18
17
16
15

PHASEA_I4
PHASEA_I3
PHASEA_I2
PHASEA_I1
PHASEA_I0
ENABLE
PHASE_A
DECAY_A

R1
3.3K

PVREF

GND

nSLEEP

JP5

V3P3OUT

C3
.47uF

MVREF REF
PVREF
XVREF

1
2
3

4
5
6

C4

R2
5K

U1
1
2
3
4
5
6
7
8
9
10
11
12
13
14

GND

C1

Header 3X2A
TL1
DRV88xx

DRV8829 uStep 32

Demo

VM

V3p3

0.1uF

0.01uF

C7
BOUT+
ISENB
BOUTBOUTISENB
BOUT+

R9
0.3

VREF

C10

1
2
3
4
5
6
7
8
9
10
11
12
13
14

CP1
CP2
VCP
VMA
OUT1
ISENA
OUT2
OUT2
ISENB
OUT1
VMB
AVREF
BVREF
GND

GND
I4
I3
I2
I1
I0
NC
EN
PH
DECAY
nFAULT
nSLEEP
nRESET
V3P3OUT

28
27
26
25
24
23
22
21
20
19
18
17
16
15

PHASEB_I4
PHASEB_I3
PHASEB_I2
PHASEB_I1
PHASEB_I0
ENABLE
PHASE_B
DECAY_B

R11
3.3K

nSLEEP
V3P3OUT

C8
.47uF

C9

U2

GND

C6

DRV88xx

J1
AOUT+
AOUTBOUT+
BOUT-

1
2
3
4

Header 4
J2
1
2
3
4

Header 4

Figure 10. DRV8828/29 Power Stage Schematic

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PCB Layout

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PCB Layout
Figure 11 through Figure 13 illustrate the recommend printed circuit board layout for this solution.

Figure 11. Top Layer Image

Figure 12. Bottom Layer Image


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13

PCB Layout

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Figure 13. PCB Silkscreen

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Following are URLs where you can obtain information on other Texas Instruments products and application solutions:
Products

Applications

Amplifiers

amplifier.ti.com

Audio

www.ti.com/audio

Data Converters

dataconverter.ti.com

Automotive

www.ti.com/automotive

DLP Products

www.dlp.com

Communications and
Telecom

www.ti.com/communications

DSP

dsp.ti.com

Computers and
Peripherals

www.ti.com/computers

Clocks and Timers

www.ti.com/clocks

Consumer Electronics

www.ti.com/consumer-apps

Interface

interface.ti.com

Energy

www.ti.com/energy

Logic

logic.ti.com

Industrial

www.ti.com/industrial

Power Mgmt

power.ti.com

Medical

www.ti.com/medical

Microcontrollers

microcontroller.ti.com

Security

www.ti.com/security

RFID

www.ti-rfid.com

Space, Avionics &


Defense

www.ti.com/space-avionics-defense

RF/IF and ZigBee Solutions www.ti.com/lprf

Video and Imaging

www.ti.com/video

Wireless

www.ti.com/wireless-apps

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