Application Note: Atmel AVR1636: Configurable PMSM Sensorless Field Oriented Control Using The XMEGA

APPLICATION NOTE
Atmel AVR1636: Configurable PMSM Sensorless Field

Oriented Control using the XMEGA
8-bit AVR Microcontrollers
Features
• 3-phase permanent magnet synchronous motor application

• Sensorless field oriented control algorithm
• Single shunt current reconstruction
• For Atmel® ATxmega16D4
• Reference design hardware and firmware
• PC based configuration utility
• Tuning guide
Introduction
This application note describes the implementation and use of a configurable 3-phase
permanent magnet synchronous motor (PMSM) kit using the ATxmega16D4
microcontroller implementing sensorless field oriented control (FOC). The complete
kit includes a 12V 3-phase PMSM, an ATxmega16D4 processor board, and a low
voltage motor control board, a USB-to-UART bridge cable, a 12V universal power
adapter, the firmware running on the ATxmega16D4, and a PC based configuration
utility.
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Table of Contents
1. Theory of operation .............................................................................. 3

1.1 Overview ........................................................................................................... 3
1.2 Hardware .......................................................................................................... 3
1.3 Firmware ........................................................................................................... 3
1.4 Configuration utility............................................................................................ 3
2. System details ...................................................................................... 3

2.1 Hardware .......................................................................................................... 3
2.1.1 3-phase PMSM ................................................................................... 4
2.1.2 Atmel ATxmega16D4 processor board ............................................... 4
2.1.3 Low voltage motor control board ......................................................... 4
2.1.4 USB-to-UART bridge cable ................................................................. 5
2.1.5 Universal power adapter ..................................................................... 6
2.2 Firmware ........................................................................................................... 6
2.2.1 Control theory ..................................................................................... 6
2.2.2 Code structure .................................................................................... 9
2.2.3 ISR routine ........................................................................................ 10
2.2.4 Communication ................................................................................. 12
2.3 Configuration utility.......................................................................................... 12
2.3.2 Layout of utility .................................................................................. 12
2.3.3 Variables ........................................................................................... 13
2.3.4 Variable plot ...................................................................................... 13
2.3.5 Parameters ....................................................................................... 13
2.3.6 File functions..................................................................................... 13
3. Running the system ........................................................................... 13

3.1 Hardware ........................................................................................................ 13
3.2 Firmware ......................................................................................................... 15
3.3 Configuration utility.......................................................................................... 15
3.3.1 Running the configuration utility ........................................................ 16
3.3.2 Motor variables and variable plot ...................................................... 17
3.3.3 Motor parameters ............................................................................. 20
3.3.4 Test run of motor .............................................................................. 24
3.3.5 Oscillator calibration.......................................................................... 25
3.3.6 mode and input_cmd parameters ..................................................... 25
3.3.7 Minimum bus voltage ........................................................................ 28
3.3.8 Voltages and currents ....................................................................... 28
3.3.9 Back EMF calculator ......................................................................... 29
3.3.10 Back EMF sensing PLL..................................................................... 33
3.3.11 Speed and theta ............................................................................... 35
3.3.12 Current regulators ............................................................................. 36
3.3.13 Speed regulator ................................................................................ 39
4. Conclusion ......................................................................................... 40

Appendix A. Atmel ATmega16D4 Processor Board Schematics ...... 41
Appendix B. Low Voltage Motor Control Board Schematics .............. 42
Appendix C. 42BLS01-001 Motor Datasheet ..................................... 43
Appendix D. Kit Parts List .................................................................. 44
Appendix E. Revision History ............................................................ 45
Atmel AVR1636: Configurable PMSM Sensorless Field Oriented Control using the XMEGA
[APPLICATION NOTE] 2
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1. Theory of operation
1.1 Overview
This application note covers the description and use of a complete 3-phase PMSM sensorless FOC system.
After reading this document the reader should have an understanding of the system hardware, firmware, and
configuration utility.
1.2 Hardware
The hardware consists of a complete motor control system. The system is composed of a 3-phase PMSM, an Atmel
ATxmega16D4 processor board, an Atmel low voltage motor control board, a USB-to-UART bridge cable and a 12V
universal power adapter.
1.3 Firmware
The firmware running on the ATxmega16D4 provides the control structure for PMSM sensorless FOC. The sensorless
control technique uses back EMF calculation to form a back EMF phase locked loop (PLL). Speed control is provided by
a proportional integral (PI) controller. The back EMF sensing PLL, the current regulators, and the speed control loop
require configuration and tuning. This is covered in Chapter 3.
1.4 Configuration utility

The configuration utility is software running on a PC provided as a tool for configuring and tuning the sensorless FOC
parameters in firmware.
Configuring consists of setting parameters that are known or calculated quantities. These quantities translate into
parameters that are set in the EEPROM. Tuning involves an iterative process of setting and testing parameters to find
the optimal value. These values are not easily calculated or involve unknown or not easily measurable quantities, so
tuning provides the most accessible method of optimization.
2. System details
2.1 Hardware
The hardware consists of the 3-phase PMSM, the ATxmega16D4 processor board, the low voltage motor control board,
the USB-to-UART bridge cable, and the 12V universal power adapter as shown if Figure 2-1.
Figure 2-1. Hardware block diagram.
USB
PC to ATxmega16D4
UART processor 3
bridge board 3-phase
PMSM
AC Atmel
Universal 12V 2.5A
low voltage motor control
power
outlet board
adapter
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2.1.1 3-phase PMSM
The 3-phase PMSM consists of a 3-phase 8-pole permanent magnet synchronous motor. The three motor leads,
consisting of one red, one black and one yellow 20 AWG wire, are brought out for connection to the low voltage motor
control board. The motor includes three Hall sensors leads plus a common sensor power and ground. These five 28
AWG wires can be left disconnected since they are not used in the sensorless algorithm.
The motor shown in Figure 2-2 is rated for 4,000 rpm at 12VDC input, the full motor specification can be found
in Appendix C.
Figure 2-2. 3-phase permanent magnet synchronous motor.
2.1.2 Atmel ATxmega16D4 processor board

The ATxmega16D4 AVR® processor board supports the microcontroller, microcontroller power, programming and
debugging, and serial communication connections.
The ATxmega processor board contains the following:
1. Atmel ATxmega16D4 AVR microcontroller.
2. 3.3V regulator to power to the AVR.
3. 6 pin header (2x3) PDI interface connector.
4. 6 pin header (1x6) for USB-to-UART bridge.
The complete schematics are shown in Appendix A.
2.1.3 Low voltage motor control board

The low voltage motor control board supports all the power and level shifting circuitry for 3-phase motor control for
various motor types and control techniques.
The low voltage motor control board contains the following components:
1. Socket for Atmel ATxmega16D4 AVR processor board.
2. Gate drive circuitry.
3. Current sense resistor.
4. 3-phase power stage consisting of three N-channel MOSFETs as lower switches and three P-channel
MOSFETs as upper switches.
5. DC bus bypass capacitor.
6. 2-pin header for 12V power adapter connector.
7. 3-pin header for motor phase connections.
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The low voltage motor control board can be configured for up to 48V nominal input voltage and 12A rms output per
phase depending on component selection. The configuration shown in Figure 2-3 and the schematics shown
in Appendix B are for the board configured for 11 to 15VDC input range and a peak output current of 6A rms.
Figure 2-3. Low voltage motor control board and an Atmel ATxmega16D4 processor board.
2.1.4 USB-to-UART bridge cable

The USB-to-UART bridge cable provides communication between a PC and the ATxmega16D4 processor board. This
cable is a standard product from FTDI. Part numbers are listed in Appendix D.
Figure 2-4. USB-to-UART bridge cable.
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2.1.5 Universal power adapter
The universal power adapter provides 12V for powering the demo board. The adapter is rated for 2.5A at 12V. The AC
power adapter uses a removable AC power connector for international use.
Figure 2-5. Universal power adapter with international plug options.
2.2 Firmware
The firmware was designed to run on the Atmel ATxmega16D4 to demonstrate a configurable motor control application
driving 3-phase PMSM with sensorless FOC.
The sensorless control algorithm updates at a rate of 128µs (7812.5Hz) this can provide sinusoidal current regulation
above 500Hz. The back EMF PLL is always enabled for robust operation that provides automatic motor starting or
recovery of the motor speed after a stall condition.
2.2.1 Control theory

The sensorless field oriented control is based on measurement of stator current and transforming these quintiles to a
reference frame rotating with the air gap flux linkage for independent control of the flux producing current (d-axis) and
the torque producing current (q-axis). A block diagram of this control structure is shown in Figure 2-6. Stator current is
measured using single shunt current reconstruction and field orientation is established using a back EMF phase locked
loop.
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Figure 2-6. Control structure.
d,q α,β
i_d_ref + i_d v_d v_a
0
Regulator v_b
PWMs
- v_c
PWM
i_q_ref
3 6
Speed Speed + i_q v_q
command Regulator Regulator
α,β a,b,c
-
Event
System
theta Back EMF
Calculation v_bus DC
speed and Bus
PLL ADC
Current
Shunt
USB
to i_sample_1
d,q α,β i_a
UART i_d i_sample_2
Bridge i_b
Serial i_c 3 phase
Communication current
2 reconstruction
3
i_q
α,β a,b,c
The field orientation to the air gap flux linkage is established by coordinate transformation (Clark transform) and vector
rotation (Park transformation) using the correct angle (theta) between a fixed reference point on the motor’s stator and
the actual air gap flux represented as a vector. This can be visualized by Figure 2-7.
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Figure 2-7. Air-gap flux linkage angle, theta.
The sensorless field oriented control is based on calculating the back EMF from stator currents and voltages, then
transforming the back EMF into the d-q reference frame that is reference by the air gap flux linkage, Figure 2-8. The
back EMF phase locked loop uses d-axis back EMF as the phase error detector, since perfect lock should produce zero
d-axis back EMF. This is based on the fact that back EMF is perpendicular to the flux linkage that generates it.
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Figure 2-8. Back EMF calculation and PLL.
2.2.2 Code structure

The code structure is shown in Figure 2-9. There are two stages: initialization and then the control loop. The
initialization takes care of all peripherals and reading of the EEPROM. The control loop is handled in an interrupt service
routine (ISR) updated every 32µs. The ISR handles single shunt current sampling, reconstruction, all FOC operations,
UART data, updating of the back EMF PLL, the speed control, and updating the pulse width modulation (PWM) outputs.
Figure 2-9. Firmware main loop.
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2.2.3 ISR routine
There is one main interrupt service routine (ISR) based off the PWM port C timer 0, triggered every 32µs. The timer
interrupt triggers an analog to digital (ADC) conversion used for single shunt current reconstruction and the ISR. The
ISR updates PWM, serial communication, and the FOC routines. Each ISR executes one fourth of the FOC routines,
giving a 128µs update rate for the complete FOC control loop. Figure 2-10, shows the PWM ISR flow.
Figure 2-10. PWM interrupt service routine.
The field oriented control routines are further broken down into three functions:
1. The back EMF phase locked loop.
2. The vector control and regulator blocks.
3. The PWM control and current reconstruction.
Each function is split between the four ISRs as shown in Figure 2-11.
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Figure 2-11. Field oriented control routines.
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2.2.4 Communication
Serial communication to the firmware allows configuration of motor control parameters stored in the EEPROM and to
allow data collection during tuning and configuring of the firmware.
A USB-to-UART bridge is used to communicate with a PC running the configuration utility.

The PC based configuration utility is for configuration and tuning of the motor performance using a virtual COM port on
the PC. The utility provides the following features:
1. Adjustable parameters for customizing the code to operate with different motors and sending these parameters
to the EEPROM.
2. A list of variables that update every 123ms.
3. A variable plot that allows watching a single variable in a scope like plotting window for performance testing.
4. An oscillator test to compare and adjust the Atmel ATxmega16D4 internal oscillator against the UART clock.
5. Simple file functions: a file load and save function for saving EEPROM values and a file save function to store
plot data.
2.3.2 Layout of utility

The configuration utility consists of a single front panel with all the functionality displayed in one window. Figure 2-12
shows the basic layout of the configuration utility.
Figure 2-12. Configuration utility layout.
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2.3.3 Variables
Variables from the firmware are sent to the configuration utility at the rate of approximately once per 123ms. The list of
variables was chosen as the most useful for configuration and tuning of the motor.
2.3.4 Variable plot

One variable from the list can be displayed in the variable plot window. This variable is sent once every 256µs which is
every other loop update. The complete plot is composed of 480 points so it is updated once every 123ms.
2.3.5 Parameters
The parameter list of values are also updated once every 123ms along with the variable list. During the configuration
and tuning process, new values can be sent to the microprocessor and the new values will be reflected in the 123ms
update. Updated parameters are stored in RAM so they are reset back to the EEPROM values after cycling power. To
store updated values the EEPROM the program button must be pressed.
2.3.6 File functions

Additional file functions are there for configuring the utility, loading and saving parameters values, and saving variable
plot data.
3. Running the system
3.1 Hardware
The system is connected as shown in Figure 3-1. Initially the Atmel ATxmega16D4 processor board can be powered
directly from the USB port, this powers up the ATxmega16D4 allowing communication with the configuration utility
without running the motor.
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Figure 3-1. Configurable 3-phase PMSM with a USB-to-UART bridge and universal power adapter connected.
Note: gold
contacts
facing up.
The PMSM phase leads are connected to the 3-pin connector J2. The motor phase leads are the 20 AWG black, red,
and yellow wires from the motor. The five 28 AWG wires are Hall sensors connections not used in this application, so
they should be left unconnected. Connecting the motor phase leads in the order shown in Figure 3-2 provides clockwise
rotation for a positive command and counter clockwise rotation for a negative command. Swapping any two phases
reverses the rotation direction for positive and negative commands.
Figure 3-2. PMSM phase leads phases a, b and c from top to bottom.
a
b
c
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DC input voltage is connected to J3 shown in Figure 3-3. The DC input range is from 0 to 15V. The gate drive ICs (U1
to U3 from Appendix B) provide an under voltage lockout below approximately 10.1V so a supply of at least 12V
nominal is recommended to run the motor. 12V power can be supplied from the universal power adapter or a variable
lab supply can be used that is capable of supplying 12V and 2.5A.
Figure 3-3. DC bus voltage input leads +Vbus and –Vbus from top to bottom.
+Vbus
-Vbus
3.2 Firmware
The following instructions are for the Atmel ATxmega16D4 processor boards that do not have firmware preinstalled or
are going to be upgraded from a previous version of firmware. This section can be skipped if firmware is already
installed. Firmware needs to be installed on the ATxmega16D4 before using the configuration utility and parameters
need to be stored in the EEPROM for the motor to run properly. There are provisions for downloads of firmware and
fuse settings through the standard six pin header, J3 using many of the common programming tools and the latest
version of Atmel Studio. Firmware can be installed using the following steps:
1. Download the AVR1636 - Firmware project.
2. Plug in USB-to-UART cable to provide 5V power to the ATxmega16D4 processor board while noting the
polarity of the connector from Figure 3-1 since this connector is not keyed.
Warning: It is good practice to not supply power to the DC bus on the low voltage motor control board while updating
firmware.
3. Connect the programmer to PC through USB connector and connect programmer ribbon cable to P1, match up
pin 1 PCB, marked by a square pad, with pin 1 on ribbon connector since the connector is not keyed.
4. Bring up latest version of Atmel Studio, example is shown with Atmel Studio 6 at the time of this writing. If you
are using a newer version of Atmel Studio, start a new C project using the GCC compiler option and select the
ATxmega16D4. Add the downloaded version of AVR1636 - Firmware.c to the project and remove the project
generated .c source file. This project is written for the GCC compiler as a single file: AVR1636 - Firmware.c
so it is easily added into a newer project.
5. Select the GCC Compiler optimization to –O2.
6. Build the solution by pressing CTRL+SHIFT+B and check for compiling errors.
9. Download the firmware by pressing the start without debugging button.
The firmware should now be running. The EEPROM parameters can be set using the configuration utility.

Once the hardware is set up and the firmware is present in the Atmel ATxmega16D4 flash memory you are ready to run
the configuration utility.
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3.3.1 Running the configuration utility
The configuration utility comes as a compressed zip file. The zip file should be extracted at the root directory (C:\). The
folder contains the executable file Atmel Motor Control Configuration Utility ver1_4_0.exe along with support files. There
is no Windows® installation, just run the .exe file.
A message in the variable plot window appears requesting that a COM port should be selected as shown in Figure 3-4.
Use the drop down box to select the COM port.
Figure 3-4. COM port box before connection.
Select COM
port.
Select
Application
configuration.
Figure 3-5 shows an example of COM port four selected. If the COM port is unknown it can be found in the Windows
start menu under Settings → Control Panel → System → Hardware → Device Manager → Ports (COM & LPT) you
should see a USB serial port (COMx), where x is the port number. After selecting the COM port, the application
configuration should be selected for AVR1636. This presents the proper variable and parameter list labels in the
configuration utility.
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Figure 3-5. COM port and application configuration boxes after selection.
3.3.2 Motor variables and variable plot

If the system is communicating with the configuration utility, the variables and parameters should fill up with values and
the variable “counter” should be changing every 123ms. If the parameter data_watch (Figure 3-6) is set to 15, the
counter variable should be displayed on the variable plot screen as a triangle waveform as shown in Figure 3-7.
Figure 3-6. data_watch parameter.
Figure 3-7. Variable plot screen displaying counter variable.
If the variable plot is not displaying counter, then the counter function is selected to the variable plot screen by
pressing the counter button, Figure 3-8.
Figure 3-8. Counter button.
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The variable plot and updates of variables and parameters can be stopped using the radio buttons shown in Figure 3-9.
This can be used to freeze data on the plot area, to read variables, and for capturing data to be saved to a file.
Figure 3-9. Data updates.
When selecting a variable for plotting the selected variable location in the list, name and description are displayed in the
variable information window, Figure 3-10.
Figure 3-10. Variable information displayed after selecting counter button.
The complete list of 16 variables is shown in Figure 3-11. The configuration utility just displays raw 8-bit values and
does not differentiate between signed and unsigned values. The first 11 variables are signed values in the firmware, but
are transmitted to the utility with the zero point offset by 128, so that positive values are greater than 128 and negative
values are less than 128.
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Figure 3-11. The variable list.
Variable select Current

button value
The variables are described in Table 3-1.
Table 3-1. Variable list description and use.
Variable Description Use

v_a Sinusoidal phase a PWM output. Used to verify sinusoidal PWM pattern is being applied to
motor on phase a.
v_b Sinusoidal phase b PWM output. Used to verify sinusoidal PWM pattern is being applied to
motor on phase b.
i_a Phase a measured current. Helps verify current reconstruction of sinusoidal feedback
current for phase a.
i_b Phase b measured current. Helps verify current reconstruction of sinusoidal feedback
current for phase b.
u_a Sinusoidal phase a voltage (scaled). Used to verify sinusoidal voltage is being applied to motor on
phase a.
ir_a IR voltage drop for phase a. Used to verify sinusoidal voltage drop is being produced from
stator resistance on phase a.
l_didt L x di/dt voltage drop for phase a. Used to verify sinusoidal voltage drop is being produced from
stator inductance on phase a.
e_a Calculated back EMF for phase a. Used to verify sinusoidal voltage is being produced from back
EMF on phase a.
i_d d-axis current aligned with air gap flux. Used to verify current regulator is controlling flux producing
component of current.
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Variable Description Use
i_q q-axis current perpendicular with air gap Used to verify current regulator is controlling torque producing
flux. component of current.
e_d d-axis component of Back EMF. Value driven to zero (=128) by back EMF PLL.
v_bus DC input voltage. Raw ADC sample of DC bus voltage. Using in calculation of
u_a.
speed Motor speed. Used to watch motor speed especially useful in back EMF PLL
tuning. speed is a signed number so 128 = zero speed.
Positive values are above 128, negative numbers are below
128.
theta Rotor angle Integral of speed. Determines angle of air gap flux.
osc_error Oscillator error Used for testing oscillator calibration against USB-to-UART
cable oscillator. osc_error is a signed number so 128 = zero
error. Positive values are above 128, negative numbers are
below 128. An invalid value = 0 is displayed before an
oscillator test has been performed. The test button must be
pressed to display a valid result.
counter Up/down counter. Used to indicate connection between configuration utility and
firmware.
3.3.3 Motor parameters

The motor parameters are EEPROM values copied into RAM on power up of the Atmel ATxmega16D4.
Figure 3-12 shows the list of parameters and the default values for the PMSM from Appendix C. If these values are not
present they can be hand entered or loaded using the parameter load button described later in this section.
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Figure 3-12. The parameter list.
EEPROM parameter in RAM

User edited value
Button transfers value to RAM.

Values are not transferred to
EEPROM until program button
is pressed.
The parameters are described in Table 3-2.
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Table 3-2. Parameter list description and use.
Parameter Description Use

v_bus_min Minimum bus voltage to enable FOC. Shuts off and resets all regulators below the threshold level
to prevent integrator windup.
osc_cal_adj Oscillator calibration adjustment. Use to fine tune factor calibration. Values from 0 to 64 alter
that calibration. Values above 64 are ignored using factory
calibration. See section on oscillator calibration adjustment
for more detail.
data_watch Selected variable in variable plot window. Used to display current selected variable or manually
update. Variables are numbered 0 to 15 from top to bottom.
mode Operation mode selection. Selects between voltage, current, and speed mode.
input_cmd Input command. Used to manually send input command, interpretation of
command depends on mode.
s_reg_rate Speed regulator update rate in number of Use to set speed regulator bandwidth below current
FOC loop updates. regulator bandwidth by slowing down the update rate.
s_reg_scaling Speed regulator scaling. Sets the number of fractional bits used in speed regulator
calculations.
s_error_limit Speed error limit. Clamps the speed regulator error.
s_k_scaling Speed gain scaling. Sets the number of fractional bits used in speed regulator
gain calculations.
s_kp Speed regulator proportional gain. Set proportional gain of speed regulator.
s_ki Speed regulator integral gain. Set integral gain of speed regulator.
i_limit Current limit. Used to set the maximum current reference that is produced
by the speed regulator output.
i_reg_scaling Current regulator scaling. Sets the number of fractional bits used in both Id and Iq
regulator calculations.
i_error_limit Current error limit. Clamps the current regulator error.
i_k_scaling Current gain scaling. Sets the number of fractional bits used in current regulator
gain calculations.
i_kp Current regulator proportional gain. Set proportional gain of current regulators.
i_ki Current regulator integral gain. Set integral gain of current regulators.
v_limit Voltage limit. Used to set the maximum voltage reference that is
produced by the current regulator output.
speed_scale Speed scaling. Value sets the scaling speed and the motor RPM. Equations
covered in the back EMF PLL section.
speed_min Minimum speed. Minimum speed of back EMF PLL. Set to reliably start up
motor from rest.
speed_max Maximum speed. Maximum motor speed of back EMF PLL. Usually set 10%
to 20% higher than no load speed of motor.
p_reg_scaling Back EMF PLL regulator scaling. Sets the number of fractional bits used in the back EMF PLL
regulator calculations.
p_error_limit Back EMF PLL error limit. Clamps the back EMF PLL regulator error.
p_k_scaling Back EMF PLL gain scaling. Sets the number of fractional bits used in back EMF PLL
regulator gain calculations.
p_kp Back EMF PLL regulator proportional gain. Set proportional gain of back EMF PLL regulator.
p_ki Back EMF PLL regulator integral gain. Set integral gain of back EMF PLL regulator.
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Parameter Description Use
p_gravity Back EMF PLL regulator gravity term. Amount of negative error added into the back EMF PLL.
Used to force the speed down to speed_min when the PLL
is not locked onto the back EMF. This is used at startup or
during a stall condition.
u_scaling Phase voltage scaling parameter. Used to set scaling of phase voltage in back EMF
calculator. See section on back EMF Calculator.
r_scaling Phase resistance scaling parameter. Used to set scaling of phase resistance in back EMF
calculator.
r_phase Phase resistance. Phase resistance, ohms per count determined by u_scaling
and r_scaling.
l_scaling Phase inductance scaling parameter. Used to set scaling of phase inductance in back EMF
calculator.
l_phase Phase inductance. Phase inductance, henries per count determined by
u_scaling and l_scaling.
The copy all buttons shown in Figure 3-13 provides a quick method to transfer all the variables between the
configuration utility and the Atmel ATxmega16D4.
Figure 3-13. Copying all parameters.
Copy all button
The white boxes on the far right column of Figure 3-12 are for editing and transferring data between the configuration
utility and files. The file transfer is a simple file saves or file load (Figure 3-14) to a text file EEPROM.txt that is stored in
the same directory that the configuration utility is launched. Backups of this file must be copied and renamed to prevent
overwriting from the utility. The default EEPROM.txt from the download should contain the parameters values
from Figure 3-12, this can be used to load the correct values.
Figure 3-14. Parameter data load and save.
To transfer the parameters stored in RAM back to the EEPROM the program button is pressed, this will ensure that the
values are preserved and are used as the default values next time the application is powered up, Figure 3-15.
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Figure 3-15. Program parameters in EEPROM.
The parameter input_cmd is used for directly sending a voltage, current, or speed command. The input_cmd
parameter is shown in Figure 3-16. The command can be directly modified using the input box on the right and then
pressing the arrow key in the middle.
Note: This only transfers the value to the RAM of the Atmel ATxmega16D4 and the program button still needs to be
pressed to commit the RAM values to EEPROM.
Figure 3-16. input_cmd direct input.
When the arrow key is pressed a description of the parameter shows up in the parameter information box, Figure 3-17.
Figure 3-17. Parameter information.
3.3.4 Test run of motor

Before running the motor the following check list should be completed:
1. Firmware is installed and running.
2. EEPROM parameters are the same as Figure 3-12.
3. The USB-to-UART cable is connected to the processor board and PC and communication is established with
the configuration utility.
4. The motor leads are connected of J2.
5. The universal power supply (or a lab adjustable power supply) is connected to J3.
Now the universal power supply is ready to be plugged or the lab supply can be turned on and brought up to 12V.
At this point the input_cmd is centered on 128 (zero command for a signed value). To start the motor input 158
(equal to +30) into the white box next to the input_cmd parameters and press the arrow button to update the
parameter. The motor should start up in a clockwise direction. The motor can be reversed by entering 98 (equal to
-30) and the arrow key pressed. The motor should reverse and run the same speed in a counter clockwise
direction.
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3.3.5 Oscillator calibration
The oscillator calibration can be checked by pressing the test button as shown is in Figure 3-18. The internal oscillator
is compared with the USB-to-UART cable oscillator which has an oscillator accuracy of better than 0.2%. See the Atmel
ATxmega16D4 datasheet for further details about oscillator calibration.
Figure 3-18. Oscillator test button.
Once the calibration button is pressed the osc_error, Figure 3-19, variable is updated. The error is centered around 128.
This means a value of 128 = zero error. A number above 128 means the oscillator is running slower than the reference
value and a number below 128 means the oscillator is running faster than the reference value. When first launching the
configuration utility, the osc_error value starts out with an invalid value of 0 so a test must be performed to get a valid
reading.
Figure 3-19. Oscillator calibration error.
The oscillator calibration can be adjusted by updating the osc_cal_adj parameter, Figure 3-20, and programming the
EEPROM. osc_cal_adj is a correction factor to the original factory calibration. The range of values is from 0 to 64,
where 32 correspond to 0 correction. If the osc_error indicate that the oscillator is running too fast you want to adjust it
down, by specifying an osc_cal_adj that is less than 32. Values from any value above 64 are ignored and only the
factory calibration is used.
The equation for Oscillator cal adjustment for osc_cal_adj < 65:
Equation 3-1
_ _ _ _ – 32
Figure 3-20. Oscillator calibration adjustment parameter, example for -15, adjustment to factory calibration.
3.3.6 mode and input_cmd parameters

The mode parameter selects how the input_cmd parameter is used, Figure 3-21. Table 3-3 shows three modes of
operation.
Figure 3-21. Mode and input_cmd parameter.
42061A−AVR−01/2013
Table 3-3. Mode options.
Mode Control mode Variable affected

0 Voltage mode (open loop PWM) v_d = 0, v_q = input_cmd
1 Current control mode i_d = 0, i_q = input_cmd
2 Speed control mode speed_cmd = input_cmd
For mode = 0, voltage mode, the control blocks used are shown in Figure 3-22. Voltage mode directly maps into the
input_cmd into the v_q variable. This mode is useful for initial tuning of the back EMF calculator and the back EMF PLL,
by eliminating any interaction with sensing and the speed and current regulators.
Figure 3-22. Mode = 0, voltage mode (open loop).
For mode = 1, current control mode, the control blocks used are shown in Figure 3-23. Current control mode set the
current reference i_q_ref to the input command and sets i_d_ref to 0. The setting of i_q_ref produces a torque
proportional to current, by regulation the torque producing component of stator current. The current regulators are
proportional integral (PI) controllers that can be tuned after the back EMF calculator and back EMF PLL are tuned.
42061A−AVR−01/2013
Figure 3-23. Mode = 1, current control mode (torque control).
For mode = 2, speed control mode, the control blocks used are shown in Figure 3-24. Speed control mode sets the
speed reference to the input command. The output of the speed regulator sets the motor toque by changing the i_q_ref
based on speed error. The speed regulator is a proportional integral (PI) controller that can be tuned after the current
regulators are tuned.
Figure 3-24. Mode = 2, speed control mode.
42061A−AVR−01/2013
3.3.7 Minimum bus voltage
The v_bus_min sets a threshold for the DC input voltage (v_bus) above which the control loops are enabled. This
prevents the speed and current regulators from winding up when the voltage is too low to properly control the motor
(due to lack of back EMF feedback signal). The scaling for v_bus and v_bus min is based on the v_bus divider and
the ADC scaling:
_ Equation 3-2
Where:
VDC = DC input voltage [volt]
Kbus = Scaling constant for variable v_bus [count/volt]
Equation 3-3
Where:
Dividerbus = Resistive divider on low voltage motor control board, Appendix B, R9 and R27.
ResolutionADC = ADC resolution used for calculation [count]
Vref = Voltage reference used for ADC [volt]
Using the values on the low voltage motor control board in Appendix B:
1
256 Equation 3-4
1 33.2
1
Equation 3-5
7.48
An example of a 10.5V (78 count) threshold is shown in Figure 3-25.
Figure 3-25. Enable voltage threshold set to 10.5V (78 count).
3.3.8 Voltages and currents

The first two variables v_a and v_b, see Figure 3-26, represent the output PWM values for phase a and phase b. Full
PWM duty cycle is set at 255 and zero percent duty cycle is set at 0. Zero output voltage is when all three phases (a, b
and c) are at 50% duty cycle or all three PWM values are set at 128. The actual output voltage is dependent on the DC
input voltage so v_a and v_b are in counts. Variable v_c is not brought out since it is the negative sum of v_a and v_b.
Equation 3-6
_
Figure 3-26. Variables v_a and v_b.
42061A−AVR−01/2013
The variables i_a and i_b, Figure 3-27, represent the measure phase current from single shunt current reconstruction
for phase a and phase b. The scaling for current is based on the current shunt value, external divider, and ADC
settings.
_ Equation 3-7
Where:
Ia = Phase a current [ampere]
Kcurrent = Scaling constant for variable i_a, i_b and i_c [counts/ampere]
Equation 3-8
Where:
Rshunt = Current sensing resistor on low voltage motor control board, Appendix B, R1 [Ω]
Dividercurrent = Resistive divider used for biasing ground referenced Rshunt voltage above ground on low voltage motor
control board, Appendix B, R29 and R14
ResolutionADC = ADC resolution used for calculation [count]
For the kit values:

10 Ω
0.05Ω 256
1 Ω 10 Ω Equation 3-9
1
11.6 Equation 3-10
Figure 3-27. Variables i_a and i_b.
3.3.9 Back EMF calculator

The instantaneous value of motor back EMF is calculated for each phase using stator quantities of voltage, current,
phase resistance, and phase inductance. The calculations in firmware uses scaled values in counts:
_ _ – _ – _ _ Equation 3-11
The physical equation for back EMF in SI units is.
– – Equation 3-12
Where:
Ea = Phase a back emf [volt]
Ua = Phase a voltage [volt]
Ia = Phase a current [ampere]
Rphase = Phase resistance [ohm]
Lphase = Phase inductance [Henry]
The back EMF calculator for one of three phases with parameters is shown in Figure 3-28.
42061A−AVR−01/2013
Figure 3-28. Back EMF calculator one of three phases with parameters.
v_a
u_a
X ÷
v_bus
u_scaling
2
+
ir_a - e_a
X ÷
-
i_a r_phase r_scaling

2
+
-1
i_a_last l_didt_a
z X ÷
-
l_phase l_scaling
2
The parameters in the back EMF calculator are shown in 0. These values need proper adjustment and scaling for
calculating the back EMF.
The scaled phase voltage, u_a, is determined by the following equation:
_ _
_ Equation 3-13
2 _
_ Equation 3-14
Where:
Ku = Scaling constant for variable u_a [count/volt]
Ua = Phase a voltage [volt]
_
Equation 3-15
2
Where:
Kbus = Scaling constant for variable v_bus [count/volts]
PWMmax = Maximum count for PWM timer [count]
2u_scaling = Scaling factor for voltage u_a, u_b, and u_c [count]
Using the example values:

7.48 256
Equation 3-16
2
14.96 Equation 3-17
42061A−AVR−01/2013
The scaled resistive drop, ir_a, is determined by the following equation:
_ _
_ Equation 3-18
2 _
_ Equation 3-19
_ ohm Equation 3-20

ohm
Where:
Kr = Scaling constant for variable r_phase [count/ohm]
_
2
Equation 3-21
ohm
Where:
2r_scaling = Scaling factor for r_phase [count]

14.96 2
Equation 3-22
11.6 ohm
165 Equation 3-23

ohm
The motor datasheet value from Appendix C for line to line resistance is divided by 2:
0.44
ohm Equation 3-24
2
_ 0.22 ohm 165 Equation 3-25

ohm
_ 36 Equation 3-26
The scaled inductive drop, l_didt_a, is determined by the following equation:

_ _ _ _
_ _ Equation 3-27
2_
_ _ Equation 3-28
_ Henry Equation 3-29

Henry
Where:
Kl = Scaling constant for variable l_phase [count/Henry]
42061A−AVR−01/2013
2_
Equation 3-30
Henry
Where:
2r_scaling = Scaling factor for r_phase [count]
freqloop = Frequency of FOC control loop [hertz]
14.96 2 7812.5
Equation 3-31
11.6 Henry
161200 Equation 3-32

Henry
The motor datasheet value from Appendix C for line to line inductance is divided by 2:
0.000510
Henry Equation 3-33
2
_ 0.000255 Henrys 161200 Equation 3-34

Henry
_ 41 Equation 3-35
Figure 3-29. Back EMF calculation parameters.
Phase a back EMF values are brought out as display variables to aid in tuning the parameters, Figure 3-30. These
values are signed numbers, so they are centered on the value 128 for display on the configuration utility.
Figure 3-30. Back EMF calculation variables for phase a.
The three phase back EMF goes through a Clarke and Park transform, Figure 3-31, for feedback to the back EMF
phase locked loop.
42061A−AVR−01/2013
Figure 3-31. Back EMF Clarke and Park transforms.
The d-axis component of back EMF, e_d is driven to zero by the back EMF PLL; this aligns the air gap flux with the d-
axis and all the back EMF is generated on the q-axis. Since e_d is a signed value it is centered on 128 for displaying on
the configuration utility. Figure 3-32 shows e_d centered at 128.
Figure 3-32. Back EMF d-axis value.
3.3.10 Back EMF sensing PLL

The back EMF phase locked loop is regulated by a PI controller where e_d is the feedback and speed is the output. The
block diagram of the calculator is shown in Figure 3-33.
42061A−AVR−01/2013
Figure 3-33. Back EMF PLL block diagram with parameters.
p_error_limit
X ÷
+ + p_k_scaling + speed
p_kp 2
0 ÷
- - +
p_gravity + p_reg_scaling
X ÷ 2
+
p_k_scaling
-p_error_limit p_ki 2 Z-1
speed_min X
p_reg_scaling
2
speed_max X
e_d
The parameters from the block diagram are listed in Figure 3-34. The parameters for the PLL are as follows:
1. speed_min and speed_max – speed range of the back EMF PLL.
2. p_reg_scaling – sets the number of fractional bits used in calculation, this can range from 0 to 7, where 5 is a
good starting point.
3. p_error_limit – clamps the amount of error that goes into the PI controller. Typical range is 8 to 32.
4. p_k_scaling – sets the number of fractional bits used in calculation of the PI gains.
5. p_kp – the proportional gain.
6. p_ki – the integral gain.
7. p_gravity – allows a small offset to force the PLL frequency to speed_min if PLL is not locked onto the back
EMF. This helps with startup of the motor. Typical values are 0 to 2.
Figure 3-34. Back EMF PLL parameters.
42061A−AVR−01/2013
Tuning a PLL regulator typically is done in mode = 0, Voltage mode, with an input_cmd fairly low so that excessive
current does not flow in the motor at stall. The input_cmd value used on this motor is set to 158 (30 above the zero
point of 128). Also the back EMF calculator must first have its values calculated and entered. Tuning the PLL is finding
the p_kp and p_ki values that give the motor quick startup and smooth steady state performance. This is done by
watching the speed variable in the Variable plot window and changing the gain values. It is best to start with setting
typical values for scaling and limits and setting the integral gain i_ki to a low value such as 1 or 2. Then increase the
i_kp gain so that the PLL tracks the motor speed.
3.3.11 Speed and theta

Speed is integrated into the angle of the air-gap flux. Integration is achieved by accumulating speed every FOC loop
update of 128µs, Figure 3-35.
Figure 3-35. The speed to theta integrator.
The result of the accumulation is scaled by the parameter speed_scale Figure 3-36. This scaling sets the frequency
range of the sine wave output voltages v_a, v_b, and v_c and as a result sets the speed range of the motor.
Figure 3-36. Speed scaling parameter.
The relationship between speed_scale and frequency is:

Equation 3-36
. . .
2 . . . Equation 3-37
_
60
2
Where:
Speed = speed_min or speed_max [unitless] (between 1 and 255)
freqloop = Frequency of FOC control loop [hertz]
thetamax = Maximum count for theta equal to 360 degrees [count]
speed_scale
2 = Scaling factor for speed [counts]
Npoles = Number of motor poles from motor datasheet, Appendix C
42061A−AVR−01/2013
7812.5 2 . . . Equation 3-38
60
256 2 8
. . . Equation 3-39
28.6
The minimum and maximum speed can be calculated replacing in speed_min and speed_max:
Equation 3-40
_ . . .
Equation 3-41
28.6 . . .
Equation 3-42
_ . . .
Equation 3-43
7293 . . .
It is important to choose a speed_scale value that ensures that the maximum speed of the motor can be reached.
For the motor included with the kit, the range is well within the no-load speed of the motor rated at 4000 [R.P.M]
from the motor datasheet in Appendix C.
3.3.12 Current regulators

There are two current regulators, one for the d-axis current and one for the q-axis current. The d-axis is aligned with the
air gap flux produced by the rotor magnets. Current along this axis can add to or subtract from the air gap flux, this is
typically used for field weakening to extend the speed range of the motor. Field weakening is not implemented so the
command is set to zero. Figure 3-37 shows the current regulator for the d-axis current, i_d and the reference set to
zero.
42061A−AVR−01/2013
Figure 3-37. i_d current regulator with parameters.
The q-axis is perpendicular to the air gap flux produced by the rotor magnets. Current along this axis produces
torque. Figure 3-38 shows the current regulator for the q-axis current, i_q and the reference set to input_cmd for mode
= 1. For mode = 2 the i_q_ref is set by the output of the speed regulator.
42061A−AVR−01/2013
Figure 3-38. i_q current regulator with parameters.
The two current regulators share the same gain settings. The parameters from the block diagrams are listed in Figure 3-
39. The parameters for the current regulators are as follows:
1. i_reg_scaling – sets the number of fractional bits used in calculation, this can range from 0 to 7, where 5 is a
2. i_error_limit – clamps the amount of error that goes into the PI controller. Typical range is 8 to 32.
3. i_k_scaling – sets the number of fractional bits used in calculation of the PI gains.
4. i_kp – the proportional gain.
5. i_ki – the integral gain.
6. v_limit – set the maximum value for v_d and v_q, the outputs of the regulators.
Figure 3-39. Current regulator parameters.
Tuning a current regulator typically starts with setting typical values for scaling and limits and setting the i_ki = 0 to turn
off the integral gain. Then increasing the i_kp gain so that the current tracks the reference, but with a DC offset. Then a
small amount of integral gains is added in until the DC offset is eliminated.
42061A−AVR−01/2013
3.3.13 Speed regulator
The speed regulator is used to modulate the torque command until the speed error is reduced to zero. The speed
regulator is a PI regulator using the same structure as the back EMF PLL and the current regulators. When mode =2
the input_cmd sets the speed reference as shown in Figure 3-40.
Figure 3-40. Speed regulator with parameters.
The speed regulator parameters from the block diagrams are listed in Figure 3-41. The parameters for the speed
regulator are as follows:
1. s_reg_rate – sets the number of current control loop updates before the speed regulator is updated, this is
due to the much lower bandwidth of the speed loop vs. the current loop. A good rule of thumb is that they
should be an order of magnitude apart. Choosing a value in the range from 10 to 50 is a good starting point.
2. s_reg_scaling – sets the number of fractional bits used in calculation, this can range from 0 to 7, where 5 is a
3. s_error_limit – clamps the amount of error that goes into the PI controller. Typical range is 8 to 32.
4. s_k_scaling – sets the number of fractional bits used in calculation of the PI gains.
5. s_kp – the proportional gain.
6. s_ki – the integral gain.
7. i_limit – set the maximum value i_q_ref, the outputs of the regulator.
42061A−AVR−01/2013
Figure 3-41. Speed control parameters.
Tuning a speed regulator typically starts with setting typical values for scaling and limits and setting the i_ki = 0 to turn
off the integral gain. Then increasing the i_kp gain so that the speed tracks the reference, but with a DC offset. Then a
small amount of integral gains is added in until the DC offset is eliminated.
4. Conclusion
This application note described the implementation and use of a configurable 3-phase permanent magnet synchronous
motor (PMSM) under sensorless field oriented control using the Atmel ATxmega16D4 microcontroller. The complete
hardware system includes a 12V 3-phase PMSM, an ATxmega16D4 processor board, a low voltage motor control
board, a USB-to-UART bridge cable, an AC power adapter, the firmware running on the ATxmega16D4, and a PC
based configuration utility for customizing the sensorless FOC for the motor.
42061A−AVR−01/2013
Appendix A. Atmel ATmega16D4 Processor Board Schematics
42061A−AVR−01/2013
Appendix B. Low Voltage Motor Control Board Schematics
42061A−AVR−01/2013
Appendix C. 42BLS01-001 Motor Datasheet
42061A−AVR−01/2013
Appendix D. Kit Parts List
Description Manufacturer Part number
Low Voltage Motor Control Board Atmel Corporation
ATxmega16D4 Processor Board Atmel Corporation
12V 4000RPM Tecmotion 42BLS01-001
USB-to-UART Bridge Cable FTDI, Future Technology Devices International Ltd TTL-232R-5V
[APPLICATION NOTE]
42061A−AVR−01/2013
44
Appendix E. Revision History
Doc. Rev. Date Comments
42061A 01/2013 Initial document release
42061A−AVR−01/2013
Atmel Corporation Atmel Asia Limited Atmel Munich GmbH Atmel Japan G.K.
1600 Technology Drive Unit 01-5 & 16, 19F Business Campus 16F Shin-Osaki Kangyo Building
San Jose, CA 95110 BEA Tower, Millennium City 5 Parkring 4 1-6-4 Osaki
USA 418 Kwun Tong Road D-85748 Garching b. Munich Shinagawa-ku, Tokyo 141-0032
Tel: (+1)(408) 441-0311 Kwun Tong, Kowloon GERMANY JAPAN
Fax: (+1)(408) 487-2600 HONG KONG Tel: (+49) 89-31970-0 Tel: (+81)(3) 6417-0300
www.atmel.com Tel: (+852) 2245-6100 Fax: (+49) 89-3194621 Fax: (+81)(3) 6417-0370
Fax: (+852) 2722-1369
© 2013 Atmel Corporation. All rights reserved. / Rev.: 42061A−AVR−01/2013
Atmel®, Atmel logo and combinations thereof, AVR®, Enabling Unlimited Possibilities®, XMEGA®, and others are registered trademarks or trademarks of Atmel
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Application Note: Atmel AVR1636: Configurable PMSM Sensorless Field Oriented Control Using The XMEGA

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APPLICATION NOTE

Atmel AVR1636: Configurable PMSM Sensorless Field

8-bit AVR Microcontrollers

• 3-phase permanent magnet synchronous motor application

1. Theory of operation .............................................................................. 3

2. System details ...................................................................................... 3

3. Running the system ........................................................................... 13

4. Conclusion ......................................................................................... 40

1.4 Configuration utility

Figure 2-1. Hardware block diagram.

Figure 2-2. 3-phase permanent magnet synchronous motor.

2.1.2 Atmel ATxmega16D4 processor board

2.1.3 Low voltage motor control board

2.1.4 USB-to-UART bridge cable

Figure 2-4. USB-to-UART bridge cable.

Figure 2-5. Universal power adapter with international plug options.

2.2.1 Control theory

2.2.2 Code structure

Figure 2-9. Firmware main loop.

Figure 2-10. PWM interrupt service routine.

2.3 Configuration utility

2.3.2 Layout of utility

Figure 2-12. Configuration utility layout.

2.3.4 Variable plot

2.3.6 File functions

3. Running the system

3.3 Configuration utility

Figure 3-4. COM port box before connection.

3.3.2 Motor variables and variable plot

Figure 3-6. data_watch parameter.

Figure 3-7. Variable plot screen displaying counter variable.

Figure 3-8. Counter button.

Figure 3-9. Data updates.

Figure 3-10. Variable information displayed after selecting counter button.

Variable select Current

The variables are described in Table 3-1.

Table 3-1. Variable list description and use.

Variable Description Use

3.3.3 Motor parameters

EEPROM parameter in RAM

Button transfers value to RAM.

The parameters are described in Table 3-2.

Parameter Description Use

Figure 3-13. Copying all parameters.

Copy all button

Figure 3-14. Parameter data load and save.

Figure 3-16. input_cmd direct input.

Figure 3-17. Parameter information.

3.3.4 Test run of motor

Figure 3-18. Oscillator test button.

Figure 3-19. Oscillator calibration error.

3.3.6 mode and input_cmd parameters

Figure 3-21. Mode and input_cmd parameter.

Mode Control mode Variable affected

Figure 3-22. Mode = 0, voltage mode (open loop).

Figure 3-24. Mode = 2, speed control mode.

An example of a 10.5V (78 count) threshold is shown in Figure 3-25.

Figure 3-25. Enable voltage threshold set to 10.5V (78 count).

3.3.8 Voltages and currents