Motor control solutions provide assistance to industry 4.0

In the trends of industry 4.0, the key factor is to promote the capacity of automatic control in factories. More importantly, motor control is an essential key to the stable operation of industrial automation.

This article introduces the motor solution presented by Arrow ESC (Engineering Solutions Center) and elaborates the key role it plays in industry 4.0.

Speed up the development of systems and promote the quality of industrial automation

With the development of industry 4.0, industrial automation will focus more on the immediate link, and collection and compilation of information in enterprises to optimize the production according to customer requirements. With remote controlled and digital factory, it allows real time control of the conditions of machine operation to ensure the stable operations of machines and safe operation of the factories. In order to achieve this goal, it is necessary to integrate I/O controllers, field instrumentation, server/driver/encoders, and other devices to grasp the operation conditions of all facilities in real-time.

To promote industry 4.0 smoothly, it is necessary to enhance the ability of data analysis, link platforms with different operating systems, and integrate all the systems. In addition, it is necessary to pay attention to the energy efficiency, safety, and other related issues. The future market will focus on the evolution of communication technology, mixing digital buses, wireless, and Ethernet networks and other technologies. Combined with fiber optics networks and automatic meter reading (ARM) systems with sensor arrays and multichannel (SAM), it allows information to be transmitted faster and more conveniently.

To satisfy the above demands, Arrow ESC has launched a CM408 motor control solution that includes power management and a core circuit board. It also comes with circuits, such as the optional current feedback, position feedback, and more to satisfy diverse needs of motor control.

The core circuit board of CM408F comes with plenty of functions, with four start modes of your choice, including No Boot, SPI Master Boot, SPI Slave Boot, and UART Boot. It is also provided with a JTAG interface for convenient online analog debugging and flash programming of the chips. It supports PWM output, with three sets (24 channels) of PWM outputs. It can control the power boards and support ADC input. There are two sets of 8-channel ADC inputs for signal collection. Providing multi-interface communication, it is equipped with RS-232, RS-485, CAN, USB, and Ethernet interface, and is equipped with a SINC filter to filter Σ-Δ ADC input signal. With the counter unit, it can collect the output signals of motor encoders and universal 32-bit timers for the collection of the output signals of electrical machine Hall Effect sensor.

The core circuit board CM408F uses an ADI CM408F processor with the support of dual channel 16-bit SAR ADC. With no missing codes, it is accurate up to 14 bits. The input voltage ranges from 0-2.5V, with conversion speed up to 380ns, applicable in high precision closed-loop control environments. Its built-in 240 MHz ARM Cortex M4 core floating point unit (32-bit single-precision floating point) can support advanced programming models and complex algorithms. Moreover, it is equipped with 384KB SRAM and 2MB flash memory for large program size, advanced PWM and timer functions for improving torque ripple and motor performance, advanced PWM generation unit, programmable PWM pulse width, programmable dead time and switching frequency, and dedicated asynchronous PWM trip signal.

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CM408F also has a built-in SINC filter for a glueless connection of AD74xx isolated converter to achieve high precision isolated current sampling. Supporting a harmonic analysis engine, it is compatible with parallel grid connections (for solar power inverter facilities). Supporting diverse interfaces, it includes Ethernet and USB interfaces as well as CANs, UARTs, SPIs, SPORTs, 32-bit timers, two-wire interfaces, and quadrature encoder interfaces. It also comes with 16-bit asynchronous memory bus that can be connected with external SRAM and FPGA. It supports an LQFP package, matching with GPIO pins and ADC input pins for optimized motor control applications. It supports ambient operating temperature up to 105 ℃, suitable for industrial use.

CM408 motor solution also connects directly with the ADI CM408F core board to control the operating dynamic control board. Using ADI high-speed magnetic isolation chips, it can isolate the control and feedback signals between the ADI M4 and the control card. It also uses IRAMS10UP60A smart power module at the highest operating voltage of 600V and highest operating current at 5A, with temperature protection function.

The operating voltage of this solution design is 390V and the maximum current is 5A. Phase current can be sampled in various ways: by the Σ-Δ ADC and the built-in SINC filter of ADSP-CM408, by the filter circuit and the built-in ADC of ADSP-CM408 with the Σ-Δ ADC used as isolation amplifier, or by Hall Effect sensor and the built-in ADC of ADSP-CM408.

The dynamic control board also supports many sensor interfaces, including Hall Effect sensor, rotary encoder, and rotary transformer for linking sensors to obtain the speed and position signal of motors. The programmable wave oscillator on the high precision rotary transformer and digital converter AD2S1210 can also provide sine wave oscillation drives for the rotary transformer.

In addition, this solution also possesses many isolation solutions, including the gate driver ADUM1310, the 16-bit ∑Δ modulator and the isolated amplifier ADC AD7403. Equipped with 1-6 channels of standard isolated digital isolators, it supports many standard isolated communications. Moreover, with an isolated DC/DC converter up to 500mW, isoPower®, and more, it ensures signal delivery without interruption and system stability.

This motor control solution developed by Arrow ESC saves customers’ time in developing their own systems and promotes the quality of industrial automation. Being the drive behind industry 4.0, it is highly recommended to users with relevant needs.

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