A MC56F8357 Based Permanent Magnet Synchronous Motor (PMSM)

Servo System

Feirong Jiang, Wei Zhang, Wenyi Liang, Xianxu Liu

College of Electrical Engineering, Zhejiang University, Hangzhou 310027, CHINA

Abstract A digital servo system based on MC56F8357 is The reference frames of FOC shown as Fig. 2 can be
presented in this paper. The system principle, hardware and used to analyze the PMSM, in the FOC, the expression of
software architectures of the AC servo drives are introduced. the voltage, flux linkage equations of PMSM in the d, q
By utilizing Field Oriented Control (FOC), Space Vector coordinate system are given as:
PWM (SVPWM), DC bus ripple compensation, digital PI
regulating with correction of the integral term and Anti-
Hunt Processing control strategies, the hardware and soft-
F 1Sd R siSd
i ±d dt
Y Sd (1fY Sq

ware of the servo system are implemented. Experiments (1)

including different position and speed control have been U Sq
YSd
=Rs ISq + YS
LdiSd Mdt
+ O)A] Sd
carried out and the experimental results are also given.
Y Sd =Ld iSd +YVM
Keywords PMSM, Servo System, MC56F8357
AI Sq =LqiSq
I. INTRODUCTION where, R, is the stator phase resistance, co is the electrical
rotor speed, Vfsd, Vfsq are d, q axis flux linkage, iSd, iSq are d,
The servo systems are commonly used in those posi- q axis current, Ld, Lq are d, q axis inductance respectively.
tioning applications require higher instantaneous torque The torque equation in d, q coordinate system is
response, lower torque ripple, wide adjustable speed
range and excellent speed regulation such as NC machine T = 2
-P(VSdiSq V4SqlSd)
(2)
tools, industrial robots, and other automation equipment, 3
e.g. printing, packaging, food, and textile machines. In
many types of AC motors, Permanent Magnet Synchro- =2[ymiJsq -(Lq -Ld )SdISq]
nous Motor (PMSM) has been considered the one better where, P is the number of pole pairs, VlM is permanent
fits servo application because the PMSM offers the ad- magnetic flux linkage. When iSd is controlled to be zero
vantage of low rotor inertia, high efficiency, efficient heat then the torque is directly proportion to iSq, and the torque
dissipation structure, and reduction of the motor size. equation should be:
Moreover, the elimination of brushes reduces noise and Te =312pymisq (3)
suppresses the need of brush maintenance. The AC
PMSM servo system has attracted more and more re-
searchers' attention.
In this paper, a digital servo system using a Digital
Signal Processor (DSP) MC56F8357 is presented. The
system principle, hardware and software architectures of
the AC PMSM servo drives are introduced, the experi-
mental results are given as well.
II. CONTROL THEORY OF THE Ac SERVO SYSTEM
The principle diagram of the PMSM servo system
base on vector control is shown as Fig. 1. In order to get
the satisfied position control, the position and speed regu- Fig. 1. Vector control based PMSM servo system principle.
lations are designed as outer loop to ensure accurate posi-
tion control and fast tracking, the current regulation with
vector control is designed as the inner loop to achieve
robust performance and fast torque response. By utilizing
Field Oriented Control (FOC), Space Vector PWM
(SVPWM), DC bus ripple compensation, digital PI regu-
lating with correction of the integral term and Anti-Hunt Proc- a oc
essing control strategies, the software of position and
speed loop control of the servo system is implemented.
The main applied strategies are considered as follow.
A. Field Oriented Control of PMSM Fig. 2. Reference frames of FOC.

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B. Voltage Space Vector PWM
The six transistors in the inverter can form eight
switch variables, corresponding to 8-space vectors: Uo,
U60, U120, U180, U240, U300, 0000, 0111, here six states are
non-zero vectors, two states (Oooo, °111) are zero vectors,
the non-zero vectors form the axes of a hexagonal, the
angle between two adjacent non-zero vectors is 60 de-
grees. The space voltage vector PWM is shown as Fig. 3.
The SVPWM method with zero vectors that combined
with states 0000 and °111 in each sector is adopt in this
paper. The inclusion of zero vectors helps to balance the
turn on and turn off periods of the transistors, and thus
their power dissipation. The objective is to approximate
the motor voltage Us by a combination of eight switching
patterns of the six power transistors. The projected motor
voltage Us, at any time, can be approximated by the vec-
tor sum of two vector components lying on the two adja-
cent basic vectors:
Us=T1 TUx+ T21TUx+60+ TnullI T(Oooo or 01 l)
T=T1+ T2+ Tnull
T is the PWM period. This approximation means that
the upper transistors must have the on and off patterns
corresponding to Ux and Ux+60 for the time T1 and T2, to
apply voltage Us to the motor, e.g., the projected motor
voltage Us is in the sector I, the time T1 and T2 of the two
vectors Uo and U60, can be calculate as
T1 = (FUua )* T / 2 (4)
UT2 =u, ET
where, u., up is a, ,B component of Us respectively
C. DC Bus Ripple Compensation
In order to eliminate the influence of DC bus voltage
ripples on the generated pulse-width-modulated wave-
forms, an arithmetic is induced to compensate the ampli-
tude of a and ,B component of the projected motor voltage
Us, the formulae are shown in (5), (6):
index *ac
F ine u ddcbus
cc u dcbus if I index* c < - 2 (5)(5)
sign(c ) * 1.0 otherwise
Undebus
i
if index * D < 2 (6)
sign (D ) *1.0 otherwise
where, index must be within a fractional range and posi-
tive: 0 <index < 1 the value depends on the modulation
technique, i.e., for the SVPWM applied in this paper, in-
dex is equal to 0.866025. 0< u dcbus< 1 is equal to 0% -
100% of the maximum DC bus voltage. The y = sign (x)
function is defined as follow:
01.0 if x O
y
1 .0 otherwise
where, x =a, , are input duty-cycle ratios and a*,,* are
output duty-cycle ratios.
D. Digital PI Regulator
If the sampling period is small enough, the incre-
mental form of normal PI algorithm is expressed as:
1520
Au(k) = u(k) -u(k -1) = Kp[e(k) -4k -1)]+KI ek) (7)
where, k is sampling order number, u(k) is the output of
the controller at the sampling time k. e(k) is input errors at
time k. Kp is the proportion, KI is integral factor. To
avoid the saturation and overflow of the regulator vari-
ables and output, one solution is to add a correction Kcor
of the integral term to the previous structure, to quickly
quit the saturation and overflow. The innovated PI algo-
rithm is as follow,
e(k)= r(k)-y(k)
u(k) =x(k-1)+Kp e(k)
x(k) =x(k-1)+±K e(k) +Kcor EpI
where, Kcor=K1 /Kp is the integral correction factor, EPI=
uour-u(k), if PI regulator is saturation and overflow,
uO1t=Umax when u(k)>Umax, or uo,t=Umin when u(k)<Umin,
otherwise uo,t=u(k).
E. Anti-Hunt Processing
In the servo control, when the motor reaches to the re-
quired position and needs to produce torque at standstill,
special attention needs paid since the rotor will very likely
oscillate (hunting). A variable gain Anti-Hunt algorithm is
developed as shown in Fig. 4. 1) When the position error
is large (region 1 or 5), the PI gains of the speed and posi-
tion regulators are set to the maximal value, to get fast
speed response. 2) When the position error is small
enough (region 2 or 4), the PI gains should be gradually
reduced. 3) Once the rotor enters the Anti-Hunt window
(region 3), the PI gains are reset to zero. This approach
has effectively avoided the rotor oscillation at the stand-
still position.
III. IMPLICATION OF HARDWARE AND SOFTWARE
U240 V. U300
(001) X (101)
[-I /,-13 [-I1/ ,1]
Fig. 3. Space voltage vector PWM.
PjIGains /
-x I O ~~I +
Position Error
Fig. 4. Variable PI gains for Anti-Hunt.
A. System Structure and Hardware Design
The MC56F8357 based servo system hardware struc-
ture is shown in Fig. 5. The hardware is mainly consisted
of a DSP MC56F8357EVM board, Power Integrate Mod-
ule (PIM) and PWM power drivers, voltage, current de-
tection and feedback circuits, position detect circuits,
LCD/LED display and indicate circuits, power supply
circuits, a PMSM servomotor with an optical encoder.
(1) MC56F8357 is a cost efficient 16-bit fixed-point
DSP of Freescale Company, up to 60 MIPS at 60 MHz
core frequency, the power supply is 3.3V.
The main characteristics of the DSP are: 1) Large ca-
pacity memory. 256KB Program Flash, 4KB Program
RAM, 8KB Data Flash, 16KB Data RAM, 16KB Boot
Flash, combined with the on-board 128KB external Pro-
gram/Data SRAM. 2) Multiple motor control modules.
Four 4-channel 12-bit simultaneous or sequential sam-
pling ADCs, the ADC internal clock is 5MHz, sample
time is 1.2us; two 6-channel independent or complemen-
tary PWM modules; two quadrature decoders for capture
the position signal; four general-purpose cascadable quad
timers and temperature sensor. 3) Mass communication
module for extend. Two asynchronous serial interfaces
SCI and two synchronous serial interfaces SPI, CAN bus
module and extend a serial RS232 communication for PC
master control and display etc.
The high calculation speed, large capacity memory,
high sample precision and strong extend capability make
MC56F8357 very optimized for digital motor control. In
this system, the calculation of FOC, SVPWM, DC bus
ripple compensation, four digital PI regulator and Anti-
Hunt processing etc are all implement in MC56F8357.
(2) A PIM P549-A-PM is adopted as the power stage,
the PIM consist of 1/3 phases input rectifier, brake chop-
per, 3 phases inverter IGBT + FRED with open emitter.
Three IR2 11 Os are used as the PWM driver circuit, so it
can use only one group power supply to control the six
IGBT inverters. If some hardware error generate, the error
signal will braking the PIM module and block all the
PWM output, the PWM drive flowchart is shown as Fig. 6.
(3) Two current LEMs (LA28-NP) and one voltage
LEM (LV28-P) are used to sense two phase current of
motor and DC bus voltage separately. The amplified and
filtered current/voltage signals are transmitted to the A/D
port of DSP. At the same time, the sample values are also
used as the hardware and software protection signals,
such as under voltage, over voltage and over current, the
detect flowchart is shown as Fig. 7.
(4) The position pulse signals from the motor optical
encoder, after anti-jamming processing, are transmitted to
the quadrature decoder of DSP. The DSP get the speed
and relative position value via calculate the pulse, at the
same time, the index signal of the encoder is use to initial-
ize alignment and correct the position offset.
(5) One 8 bit LCD (W-C1601A) is used to display
the position, speed, voltage, current value and other vari-
ant if needed. LEDs are also used to display the system
1521
Voltage 12 FOC<
Current bit_9
T
Display Si _R
| u/top + G < 1 E Quadrature/
Up speed 0 PM
Freescale DSP
D
E
Down speed MC56F8357EVM R
Fig. 5. MC56F8357 based servo system hardware structure.
IPWMDv OpticaleC j1 PWM
Fig. 6. PWM drive flowchart.
Fig. 7. Voltage/current detect flowchart.
state, e.g. run/stop motor, up/down speed when press the
corresponding buttons. Besides, a Human Machine Inter-
face (H4MI) is extended via an electrically isolated serial
RS232 communication, to control the motor and display
system state in real-time.
(6) In the power supply circuits, digital and simula-
tive power grounds connected by one point in this servo
system, the different groups of power supply are isolated
by optically coupled isolator, the different powers level
translation are also used in this system.
B. Software Design
The main idea of the servo control program in this pa-
per is: 1) Calculate the position error of the required posi-
tion and the actual position, which return back by the po-
sition interrupt program. After Anti-Hunt processing, the
position PI controller generates a required speed by the
position error. 2) Calculate the speed error of the required
speed and the actual speed, which is calculated by M1T
algorithm. Then the speed PI controller generates a re-
quired current by the speed error. 3) Calculate the actual
currents in d, q coordinate system by the ADC interrupt
program, then compare to the required currents, the cur-
rents PI controller generate the required output voltages. 4)
Eliminate DC bus voltage ripple, then generate PWM
signal drive the servo motor by SVPWM.
The control program flowchart of servo system is
shown as Fig. 8, it consists of the main program, ADC
and position interrupt program. In the main program, ini-
tialization DSP, fault control, application control and
brake control and performed In the ADC interrupt pro-
gram, the analog sensing processing, sin, cos generation,
current control and PWM output are performed, the inter-
rupt period is 125us. In the position interrupt program,
position/speed measurement, alignment control, position
control and speed control processes are performed. The
interrupt period is 3ms.
In order to control the motor and detect the parameters
more convenient, a graphic user interface is programmed
 Fb_SiZMmzNa\+evg=w.A8VjP-0EltfI?X;hWs*ibFrS_
with the PC master. The PC master, which extended via control have been carried out. The parameters of the PM
an electrically isolated serial RS232 communication, is servomotor are as follow: PN=4, T,1=0.59 N m, Rw=27.15
plug in the program software for Freescale DSP. The pro- Ohm, Lw=45 mH, Jm=0.027 kgm2 103, P11=201 W, I 1 A.
grammed HMI is shown as the Fig. 9. An embedded incremental encoder with a resolution of
1024 lines/r (the quadruple frequency is 4096 lines/r) pro-
IV. EXPRIMENT RESULTS vides position and speed feed back for servo control.
The PWM frequency is 8 KHz, DC bus voltage is 36
The experimental equipment is shown in Fig. 10. It V, voltage and current sampling period is 125 us, speed
contains a PMSM servo motor, a MC56F8357EVM board and position sampling period is 3ms, PC master sampling
and a parameter detection and drive board. Ranges of ex- period is lOims, the HTML control form of the PC master
periments including current, different speed and position refresh period is 1 s.
Star
The steady state and transient state phase currents re-
Initialization (ADC Interrupt) spondent waveforms are shown in Fig. 11 and Fig. 12 sepa-
Enable Interrupt Analog Sensing Processing
rately. It can be seen that the precise sinusoidal wave-
Currents sensing ia, ib forms are obtained. The id, iq currents respondent wave-
|Voltage sensing-DC bus|
Fault Control forms with sudden load and unload, obtained from the PC
Undervoltage
Overheating Sin, cos Generation master, are shown as Fig. 13. These waveforms proved
Overvoltage
Overcurrent the high control performance and fast torque response.
Current Control
Currents transformation (a,b,c to d,q)
The speed respondent waveform from 20 rpm to 200
Application Control Current d regulator PI controller rpm, final 600 rpm is shown as Fig. 14. It indicates a fast
PC Master/Manual control Current q regulator PI controller
Run/stop control Voltages transformIation (d,q to no
DCBus ripple compensation
and steady speed respond.
Alignment control
Position/speed loop control SVPWM Module sets duty circle
Up/down speed control
LED indication control
LCD display control PWM Output
Brake Control
( Return o)
A. Main program flowchart B. ADC interrupt program

Fig. 10. Prototype of experimental set up

.r r r r r. r. I.r. .r .r 1

,..

C. Position interrupt program

Fig. 8. Servo system control program flowchart.
lrllW m qtl .P 5H' . S Ie ,J ...

Fig. I11. Phase currents waveform at steady mode (0.2 A/grid).

T
.
. _t
s *

=-Bs--RyM-1ffi-f]'i't-Be
lsb \? th76
Br0b-*--1bB *0t>-Sh1.
gr at
. W. .t g

ffi X g ii

k W A M

_
l}is;-
l2;e1
_ P_ |R _

W Eg ' H XR tS4mS .
I
B __ _
Fig. 9. PC master control and display interface. Fig. 12. Phase currents waveform with abruptly strike (0.2 A/grid).

1522
 The different position respondent waveforms obtained
from the PC master when change position setting: 1)
From 0 pulse to 1000 pulses is shown as Fig. 15. 2) From
0 pulse to ±20000 pulses, then -20000 pulses, fmnal 0
pulse is shown as Fig. 16. ('±' means clockwise, '-' Actual Positionl
means anticlockwise). They verified that the servo control
can run in four quadrants very well, the position error is
very small (only one line error, 4096 lines/r) and the R~cjuired Po ition
speed response is fast.
The experimental results show that the servo system
proposed can accomplish precise position and speed con-
trol with fast torque respondent.

16. Position respondent wavetorm when change position from 0

pulse to 20000 pulses, then-20000 pulses, final 0 pulse.

V. CONCLUSION

According to the experiment results, it can be con-

cluded that:
The servo system using MC56F8357 as the DSP con-

troller needs fewer elements but has higher performance a

cost ratio. The intelligent program compiler, friendly hu-

man control interface and reliable fault tackle ability
make the servo control more convenient. MC56F8357 is
an ideal selection for digital motion control.
Fig. 13. Current qwvform with load and without abruptly load. By utilizing DC bus ripple compensation, digital PI
regulating with correction of the integral term and Anti-Hunt

Processing control strategies, the functions, performance,

control precision and the anti-disturbance ability of the

md o d nd servo system have been greatly improved.

The servo system proposed has been proved to be ro-

bust and effective with very reasonable cost.

AcKNOWLEDGMENT

The authors are grateful to the Freescale Company for

supporting this research.

REFERENCES

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DSP-based software AC servo systems with PM synchronous mo-

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[3] Libor Prokop, and Pavel Grasblum, 3-Phase PM Synchronous

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[6] Hyung-Tae Moon, Hyun-Soo Kim, and Myung-Joong Youn, A

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1523