TIDA-00285 Reference Design

Texas Instruments

1-kW/36-V Power Stage for Brushless Motor in Battery Powered Garden and Power Tools Reference Design

Description

This reference design is a power stage for brushless motors in battery-powered garden and power tools rated up to 1 kW. The power stage operates from a 10-cell lithium-ion battery with a voltage range from 36 to 42 V. The design uses CSD18540Q5B NexFETs featuring a very low drain-to-source resistance (RDS_ON ) of 1.8 mΩ in a SON5x6 SMD package: which results in a very small form factor of 57 × 59 mm. The three-phase gate-driver DRV8303 is used to drive the three-phase MOSFET bridge: which can operate from 6 to 60 V and support programmable gate current with maximum setting of 2.3-A sink / 1.7-A source. The power stage can be configured for a single-shunt or three-shunt current sensing. The design supports sensorless control for brushless DC (BLDC) and permanent magnet synchronous motors (PMSM) using trapezoidal control or field oriented control (FOC). The C2000™ Piccolo™ LaunchPad™ is used with the power stage to implement InstaSPIN™-FOC using the motor current and voltage feedback. The corresponding test report evaluates the thermal performance of the board and overcurrent protection features such as cycle-by-cycle control and latch control of the DRV8303.

Features
  • 1-kW Power Stage with Field Oriented Control for Permanent Magnet Synchronous Motors: Designed to Operate from 10-Cell Li-Ion Battery Voltage Ranging from 30 to 42 VDelivers up to 30-A RMS Continuous Motor Current with an Airflow of 400 LFMSmall PCB Form Factor of 57 × 59 mm using 60- V/400-A PEAK: 1.8-mΩ RDS_ON: SON5x6 Package MOSFETs for Power StageUses DRV8303 Three-Phase Gate Driver: Which Can Operate from 6 to 60-V Input: Supporting Programmable Gate Current With Maximum Setting of 2.3-A Sink / 1.7-A SourceOvercurrent Protection Configurable for Cycle-by- Cycle Control or Latch ShutdownDesigned to Operate at an Ambient Temperature of –20 °C to 55 °C
Applications
  • Electric bike
  • Cordless vacuum cleaner
  • Cordless power tool
  • Coffee machine
  • Mixer
  • blender & food processor
  • Air conditioner outdoor unit
  • Vacuum robot
  • Cordless handheld garden tool
  • DC-input BLDC motor drive
  • Mains powered tools
  • Lawn mower
  • Robotic lawn mower
  • Humanoid
  • Electric scooter
  • Proximity sensor
Product Categories
  • Amplifiers

Parts

Part Number Name Companion Part
DRV8303 DRV8303 Buy Datasheet
LMT84 LMT84 Buy Datasheet
OPA2374 OPA2374 Buy Datasheet
TMS320F28027F TMS320F28027F Buy Datasheet
TPD4S009 TPD4S009 Buy Datasheet
TPS54061 TPS54061 Buy Datasheet

Bill Of Materials

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Schematic

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Test Data

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Other Documents

Title Updated Type Size (KB)
TIDA-00285 Gerber 12 Feb 2015 ZIP 1119
TIDA-00285 Design File 12 Feb 2015 ZIP 6720
TIDA-00285 PCB 12 Feb 2015 PDF 1750
TIDA-00285 Assembly Files 12 Feb 2015 ZIP 192
TIDA-00285 BOM 12 Feb 2015 PDF 22
TIDA-00285 Schematic 12 Feb 2015 PDF 716