Reference Design

Motor Control

Complete motor control reference design with advanced algorithms, multi-motor support, and comprehensive safety features for precision control.

Overall Project Overview

What We Built

High-performance motor control system with field-oriented control, multi-motor support, and advanced safety features for industrial and automotive applications.

• Support for BLDC, PMSM, and ACIM motors up to 5kW
• Field-oriented control with sensorless operation
• Multi-axis coordinated motion control
• Comprehensive safety monitoring and protection
• Real-time communication interfaces (EtherCAT, CAN)

Requirements & Design Philosophy

High Performance: Precise control with minimal torque ripple and fast dynamic response

Safety Critical: Multiple safety layers with redundant monitoring and safe torque off capability

Efficiency: Optimized algorithms for maximum motor efficiency across operating range

Reliability: Industrial-grade components with extensive environmental testing

Flexibility: Configurable for different motor types and application requirements

System Architecture

Modular motor control architecture with dedicated processing for real-time control and system management:

• Motor Control Processor: High-performance DSP for real-time control algorithms
• Power Stage: Three-phase inverter with integrated gate drivers and protection
• Feedback Sensors: Encoder, resolver, and Hall effect sensor interfaces
• Communication Module: Industrial Ethernet and fieldbus connectivity
• Safety Controller: Independent safety monitoring with SIL3 certification
• Power Management: Regenerative braking and efficient power conversion

Hardware

Platform Choice

Zion Platform (Xilinx Zynq-7000) - Selected for FPGA-accelerated motor control algorithms and real-time processing.

Why chosen: FPGA fabric for high-speed PWM generation and custom control loops, ARM processors for system management

Hardware parameters: XC7Z020 SoC, dual-core ARM Cortex-A9, Artix-7 FPGA fabric

Design Considerations

Form Factor: Compact design (120mm x 100mm) with integrated cooling and EMI shielding

Power Requirements: Wide input voltage range (12-48V DC) with high-efficiency power conversion

Environmental Constraints: -40°C to +85°C operation, vibration resistance per IEC 60068-2-6, IP65 protection

Requirements & Design Philosophy: Reinforced isolation for high-voltage applications, thermal management for continuous operation

OS/Firmware

OS Chosen & Configuration

FreeRTOS with real-time extensions - Selected for deterministic control loop execution and low latency.

Why chosen: Hard real-time scheduling for control algorithms, minimal jitter for precise motor control

Kernel configuration: Priority-based preemptive scheduling, optimized interrupt handling for control loops

OS configuration: Static memory allocation, no heap to ensure deterministic behavior

Drivers & Requirements

Drivers developed: High-resolution PWM drivers, encoder interface drivers, EtherCAT slave stack, safety I/O drivers

Requirements & Design Philosophy: Synchronized sampling for sensor fusion, phase-locked loops for frequency control, watchdog protection for continuous operation

Middleware

Middleware Chosen

Motion Control Framework - Custom middleware stack optimized for multi-axis motor control and industrial communication.

Why chosen: Purpose-built for motion control with proven performance and reliability

Requirements & Design Philosophy: Deterministic data flow with guaranteed latency, modular design for easy configuration

Interfaces

Motor Interfaces: Three-phase power connections with current sensing and temperature monitoring

Communication Interfaces: EtherCAT, CANopen, and Modbus for industrial networking

Control Interfaces: Standardized APIs for motion profiles, PID tuning, and safety functions

Application

Applications Developed

Advanced Motor Controller - Comprehensive motor control software with multiple control modes and safety features.

• Field-oriented control with space vector modulation

• Sensorless operation using back-EMF estimation

• Multi-axis synchronization for coordinated motion

• Advanced safety functions with STO and SS1 implementation

Interfaces & Requirements

Interfaces: Industrial Ethernet APIs for PLC communication, CAN bus interfaces for vehicle integration, REST APIs for configuration

Requirements & Design Philosophy: Fault-tolerant operation with automatic error recovery, comprehensive diagnostics for predictive maintenance, modular design for different motor types

Support Apps

Desktop

Motor tuning and configuration software for PID parameter adjustment, oscilloscope tools for waveform analysis, and diagnostic utilities with real-time monitoring.

Cloud

Fleet monitoring platform for motor performance analytics, predictive maintenance scheduling, and remote parameter optimization.

Mobile

Field service apps for motor diagnostics, commissioning tools for initial setup, and monitoring apps for maintenance technicians.

Other Support

Cloud Interface & Diagnostics

Advanced cloud connectivity for motor system monitoring, diagnostics, and performance optimization.

• Secure industrial IoT connectivity with MQTT and OPC UA

• Real-time motor telemetry for performance monitoring

• Automated diagnostics with vibration analysis and current signature analysis

• Historical data analytics for predictive maintenance and optimization

Profiling & Requirements

Performance Profiling: Efficiency analysis, thermal profiling, and control loop optimization tools

Requirements & Design Philosophy: Comprehensive testing with automated validation, detailed logging for failure analysis, continuous monitoring for long-term reliability

Final Overview

What Will Be Delivered

Complete production-ready motor control solution with hardware, software, documentation, and support tools.

• Assembled and tested motor control hardware
• Complete firmware and control algorithms
• Comprehensive safety certification documentation
• Configuration and tuning tools
• Integration guides and API documentation
• Technical support and training services

Requirements & Design Philosophy

Production Ready: All components meet industrial standards and safety certifications

Customizable: Flexible architecture supports different motor types and power ratings

Reliable: Multiple safety layers ensure safe operation under fault conditions

Efficient: Optimized control algorithms for maximum efficiency and performance