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Everest CORE - Product Manual |

Product Description

INGENIA | 08/01/2019

6

4. Product Description

Everest CORE is a high power, highly-integrated, digital servo drive intended to be plugged or soldered to an
application-specific daughter board. The drive features best-in-class energy efficiency thanks to its state of the art
power stage, and can be easily configured with Ingenia's free-to-download software

MotionLab 3.

Everest CORE can be interfaced by means of its proprietary

Motion Control Bus

protocol.

Main features:

•

Ultra-small footprint

•

80 V

DC

, 30 A

RMS

continuous

•

Up to 99% efficiency

•

Up to 75 kHz current loop, 25 kHz servo loops

•

10 kHz ~ 100 kHz PWM frequency

• 16 bit ADC with VGA for current sensing
•

Supports Halls, Quadrature encoder, SSI and BiSS-C

•

Up to 4 simultaneous feedback sources

•

Full voltage, current and temperature protections

Typical applications:

•

Collaborative robot joints

•

Robotic exoskeletons

•

Wearable robots

•

AGVs

• UAVs
•

Industrial highly integrated servomotors

•

Smart motors

•

Battery-powered and e-Mobility

•

Low inductance motors

4.1. Part numbering

Product

Ordering part
number

Status

Image

Everest CORE

Pluggable servo drive with
communication through proprietary

M

otion

C

ontrol

B

us protocol.

EVE-CORE

For applications requiring a pluggable drive enabled with EtherCAT or CANopen, please see

For applications requiring a ready-to-go product, also enabled enabled with EtherCAT or CANopen, please

PRE-PROD.

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Summary of Contents for Everest CORE

Page 1: ...INGENIA CAT S L AVILA 124 08018 BARCELONA Everest CORE Product Manual Edition 08 01 2019 For the most up to date information visit the online manual ...

Page 2: ... Feedback connector 13 5 4 P4 Everest CORE Interface connector 16 6 Dimensions 21 7 Application Guide 22 7 1 Scope and Architecture 22 7 1 1 Parts of an Everest CORE integration solution 22 7 1 2 Single Axis or Multi Axis approach 22 7 2 Schematic Design 22 7 2 1 Input Supplies 23 DC Power Supply 23 DC Bus input stage 24 Logic supply 27 7 2 2 Protective circuits 30 Inverse Polarity Protection 30 S...

Page 3: ...nalling 49 Schematic 50 Signals description 50 Design Notes 50 Bill of materials 50 7 3 Layout Design 50 7 3 1 Required files 51 7 3 2 The Everest CORE component 52 Mechanical layer 5 positioning guide 52 Mechanical layer 15 clearances 53 7 3 3 Layout considerations 54 Proposed Layer Stack 56 Proposed Design Rules 57 8 Service 58 ...

Page 4: ...t or in other documents mentioned in this document The text and graphics included in this document are for the purpose of illustration and reference only The specifications on which they are based are subject to change without notice This document may contain technical or other types of inaccuracies The information contained within this document is subject to change without notice and should not b...

Page 5: ...pment power source wait at least 10 seconds before touching any parts of the controller that are electrically charged or hot 3 3 Precautions The following statements should be considered to avoid serious injury to those individuals performing the procedures and or damage to the equipment The Everest Servo CORE Drive components temperature may exceed 100 ºC during operation Some components become e...

Page 6: ...rvo loops 10 kHz 100 kHz PWM frequency 16 bit ADC with VGA for current sensing Supports Halls Quadrature encoder SSI and BiSS C Up to 4 simultaneous feedback sources Full voltage current and temperature protections Typical applications Collaborative robot joints Robotic exoskeletons Wearable robots AGVs UAVs Industrial highly integrated servomotors Smart motors Battery powered and e Mobility Low i...

Page 7: ...inal phase continuous current RMS 30 A Maximum phase peak current RMS 60 A 3 sec Active current limiting based on power stage and motor temperature Efficiency Up to 99 20 kHz 80 V 30 A Bus voltage utilisation 97 20 kHz 80 V voltage mode no load Motion control specifications Standby logic supply consumption 1 W Measured with commutation turned OFF Supported motor types Rotary brushless SVPWM and Tr...

Page 8: ...ronous Velocity Cyclic Synchronous Current Profile Position trapezoidal s curves Profile Velocity Interpolated Position P PT PVT Homing Inputs outputs and protections General purpose Inputs and outputs 4 x non isolated single ended digital inputs 3 3 V logic level Can be configured as General purpose Positive or negative homing switch Positive or negative limit switch Quick stop input 4 x non isol...

Page 9: ...rcuit Phase to GND Configurable protections DC bus over voltage DC bus under voltage Drive over temperature Drive under temperature Motor over temperature requires external sensor Current overload I2 t Configurable up to Drive limits Voltage mode over current with a closed current loop protection effectiveness depends on the PID Motion Control protections Halls sequence combination error Pending i...

Page 10: ...t CORE can output provided that an active derating algorithm will be continuously protecting it from thermal over stress Notice that PWM commutation frequency cannot be changed dynamically but pre selected to match the application needs most probably 10 kHz will be selected for highest current at a given temperature be aware that selecting this frequency may cause audible noise but 100 kHz will be...

Page 11: ...2019 11 Following figure show the theoretical power losses at different operating points Take a look to the Thermal Dissipation section below to learn how to dimension a heatsink to allow Everest CORE reaching a target current under an specific ambient temperature ...

Page 12: ...out 5 1 Connectors Overview 5 2 P1 and P2 Power pins P1 Supply Power pins Pin Name Type Function 1 POW_SUP Power Power supply positive DC bus 2 GND_P Power supply negative Power Ground Chassis PE Protective Earth connected to driver housing and fixing M2 5 threads ...

Page 13: ...fixing M2 5 threads Everest CORE connector Recommended mating contact Description Up to 11 2 ARMS rated motors Ø 1 52 mm 4 mm pitch gold plated power pins Beryllium copper TH pin receptacle Gold plated Mill Max 9372 0 15 15 23 27 10 0 11 2 ARMS rated motors Direct solder to PCB TH pad with min hole Ø 1 63 mm Ensure PCB track are wide enough to withstand the target current 5 3 P3 Feedback connector...

Page 14: ...rved Do not connect leave floating 9 DNC 10 DNC 11 DNC 12 DNC 13 MOTO R_TEM P Motor temperature sensor input 0 V to 5 V level high impedance input 12 bit single ended analog input 14 DNC 15 GND_D Digital signal Ground Power 16 NC Internally not connected Recommended to leave them unconnected 17 HALL_ 1 Digital hall 1 Input 18 NC 19 HALL_ 2 Digital hall 2 20 GND_A Analog Ground Do not connect to GN...

Page 15: ...ute Encoder 1 Output 39 DNC 40 ABSEN C1_DA TA Data input for Absolute Encoder 1 supports SSI or up to 2 BiSS C encoders connected in daisy chain topology Input 41 DNC 42 DNC Reserved Do not connect leave floating 43 DNC 44 GND_D Digital signal Ground Power 45 DNC 46 DNC Reserved Do not connect leave floating 47 DNC 48 DNC 49 DNC 50 DNC 51 DNC 52 DNC 53 DNC 54 DNC 55 DNC 56 DNC 57 DNC 58 DNC 59 GND...

Page 16: ...L must be tied or pulled up to 3 3 V Manufacturer Everest CORE connector Required mating connector Description Hirose Electric 60 pin mezzanine stacking board connector 0 5 mm pitch Center strip gold plated surface mount contacts 3 mm stacking height DF12 3 0 60DP 0 5V 86 DF12 3 0 60DS 0 5V 86 5 4 P4 Everest CORE Interface connector Although using the same physical connector as Everest NET EVE NET...

Page 17: ...n this pin could cause failure or even permanent damage to the Everest CORE Power output 10 3 3V_D 3 3 V 250 mA max output to supply peripherals An excessive current demand on this pin could cause failure or even permanent damage to the Everest CORE Power output 11 GND_D Digital signal Ground Power 12 GND_D Digital signal Ground Power 13 GND_D 14 MCB_S PI_MIS O Motion Control Bus Master input Slav...

Page 18: ...er 40 DNC Reserved Do not connect leave floating 41 EXT_F AULT External fault input Could be configured to force the Everest CORE state machine to the Fault state motor will be stopped when the pin is driven to 0 V Includes an internal weak pull up although external pull up to 3 3 V is advised Input 42 PWM_ BRAKE PWM output for driving a mechanical brake Configurable up to 20 kHz High level indica...

Page 19: ... loss of performance or even malfunction of Everest CORE route by following the best layout practices 78 DNC Reserved Do not connect leave floating 79 GND_A Analog Ground Do not connect to GND_D directly use a ferrite bead or 1 Ω resistor in between Power 80 GND_A Analog Ground Do not connect to GND_D directly use a ferrite bead or 1 Ω resistor in between Power Notes and naming conventions All pin...

Page 20: ... Manufacturer Everest CORE connector Required mating connector Description Hirose Electric 80 pin mezzanine stacking board connector 0 5 mm pitch Center strip gold plated surface mount contacts 3 mm stacking height DF12 3 0 80DP 0 5V 86 DF12 3 0 80DS 0 5V 86 ...

Page 21: ...Everest CORE Product Manual Dimensions INGENIA 08 01 2019 21 6 Dimensions All dimensions are in mm All tolerances 0 2 mm 3D Model For further detail download the STEP model ...

Page 22: ...ng at high ambient temperatures would require to thermally attach the Everest CORE to a heatsink 7 1 2 Single Axis or Multi Axis approach The simplest way to integrate Everest CORE is to develop an interface board to hold 1 drive module and a Master device This way the Master can command the Everest CORE as a slave and the Everest CORE will control the motor accordingly The Motion Control Bus prot...

Page 23: ...oper voltage current and power of this supply is typically not as simple as checking the specifications of the target motor In fact in most cases the nominal values of the motor will be substantially different from the analogous values of the power supply To learn more about this check out the following documents How to dimension a power supply for an Ingenia drive Understanding why the motor phas...

Page 24: ...could be done up to 2 decades or even more The selected values just pretend to be indicative of this This capacitors should be of X type ceramic and their voltage must be carefully selected to match the application under a safety criteria keep in mind that capacity of ceramic capacitors experience a strong derating over voltage Decoupling capacitors to Earth C9 and C10 are of crucial importance Th...

Page 25: ...acity externally as close as possible to the Everest CORE to get a reasonable performance in a mid range application Low frequency ripple is more likely to increase when the Everest CORE is driving a low inductance motor specially when driving it at high currents This ripple can get to carry a lot of energy and therefore a larger capacity would be required Here ceramic capacitors are still the bes...

Page 26: ...If any of this reflections could reach a dangerous level the TVS would get rid of it With all this the following generic solution is proposed Schematic Ceramic and optional electrolytic capacitors Sourge and ESD protection Signals description Signal Description POW_SUP_IN Positive terminal of the power supply input POW_SUP_IN Negative or reference voltage terminal of the power supply input POW_SUP...

Page 27: ...ytic capacitor 150 µF 200 V 40 ºC 105 ºC MTBF 1000h 105 ºC 1 89 A 100 kHz current ripple C14 C15 C16 C17 C18 C19 C5750X7S2A106K23 0KB TDK 2220 Ceramic capacitor 10 µF 100 V X7S C20 C21 C22 C23 C2012X7S2A105K12 5AE TDK 0805 Ceramic capacitor 1 µF 100 V X7S C24 C25 HMK212B7104KG T TDK 0805 Ceramic capacitor 100 nF 100 V X7R D1 SMLJ70CA Bourns SMC DO 214 AB Bidirectional diode TVS 70 V standoff 113 V...

Page 28: ...ing and to focus the attenuation in the highest frequencies 5 V logic supply DC DC requirements Input voltage set by application 100 V will cover any possible scenario Output voltage 5 V Output regulation 2 or less Max ripple 200 mVp p or less Output current 300 mA continuous 500 mA continuous preferred Isolation voltage 1 5 kV recommended although not mandatory in some cases Ingenia is committed ...

Page 29: ...is a unidirectional TVS meaning that in case of inverse polarity of the 5 V input this will conduce in direct mode Then either the power supply voltage will drop once reached the maximum current or the TVS will burn if the power supply is powerful enough This behaviour is intended as it works as a very basic inverse polarity protection in addition to its main ESD protection function 5V_D must be c...

Page 30: ... BLM18SG221TN1D Murata 0603 2 5 A ferrite bead 220 Ω 100 MHz 40 mΩ DC U1 LD1117S33CTR ST Microelectroni cs SOT 223 4N 15 V max input LDO fixed 3 3V output 800 mA 7 2 2 Protective circuits Inverse Polarity Protection This circuit is intended to block any current going into Everest CORE when the power supply is connected in inverted polarity If this circuit is not present it is suggested to select a...

Page 31: ...or during longer periods of time when the load is driving the motor like it would happen when a hoist is overloaded In this cases although an inverter typically works as a step down it will behave as a step up and could elevate the voltage of the internal DC bus even beyond its maximum ratings causing permanent damage to the drive and leaving the load completely uncontrolled Therefore this is an o...

Page 32: ...tor which is costly and space consuming This method can be implemented with the circuit proposed below To learn more about motor re injection and how to dimension the power resistor check the following document Dimensioning a Shunt Resistor for Regenerative Braking Schematic Signals description Signal Description 5V_D 5 V Logic supply OVERVOLTAGE To be connected to any of the GPOx pins of Everest ...

Page 33: ...wirewound type of resistor Bill of materials Designato r Part Number Manufacturer Package Value Description C1 GRM155R71C104KA88 D Murata 0402 Ceramic capacitor 100 nF 16 V X7R D1 SK310A LTP Micro Commercial SMA DO 214AC Diode Schottky 3 A 100 V Q1 BSZ150N10LS3 G Infineon TSDSON 8 Logic level N Channel MOSFET 100 V 40 A R1 CRCW040247R0FKED HP Vishay 0402 Thick film resistor 47 Ω 1 tolerance 1 5 W ...

Page 34: ... circuits but could be wired separately Zener diodes D1 and D2 provide 2 protective functionalities at the same time First they protect against overvoltage of the optocopupler s emitter by saturating voltage thanks to the current limited by resistors R1 and R3 This also expands the operating range of the input to 24 V levels 30 V maximum Second they protect against inverted polarity of the input v...

Page 35: ...rance 1 16 W U1 U2 TLP293 BL TPL E Toshiba 4 SOIC Transistor output optocoupler 3750 Vrms isolation 50 min CTR 7 2 3 Inputs and Outputs Digital Inputs Simple solution to adapt a rather wide range of input voltages to 3 3 V levels Schematic A resistor limits the current while a Zener diode saturates the voltage Everest CORE will detect as low any voltage lower than 0 8 and as high any voltage great...

Page 36: ...in 58 of Everest CORE Interface connector GND_D Logic supply reference voltage To be connected to pins 59 and 60 of Everest CORE Interface connector Design Notes For simplicity the proposed solution is not opto isolated Therefore the input signals generator could be a PLC or other controller must share the Ground with Everest CORE 24 kΩ is not a random value It is intended to fit the voltage curre...

Page 37: ...A Designator Part Number Manufac turer Pack age Value Description Digital Outputs This simple circuit can be used to convert the 3 3 V push pull digital outputs of Everest CORE into 5 V open collector with weak pull ups This will invert the logic polarity of the output but at the same time it will provide the capability of driving greater loads Schematic The following circuits should allow driving...

Page 38: ...ed to the output Although it is an output it will work by sinking current The positive terminal of the load would be connected to a power source which Ground terminal is shared with Everest CORE When using the load in push pull configuration the 1 kΩ resistor set the output impedance and limit the current In this case note that the polarity of the GPOx signal coming from Everest CORE will be inver...

Page 39: ...t be tied to GND_P If the DC bus is supplied at 24 V or less the signal BRAKE could be tied to SUP_PROTECTED or externally connected to the positive terminal of the power supply The net tie between the GND_D and the GND_P allows sharing the same reference voltage while controlling the return path in the layout phase As a solenoid is a highly inductive load the wheeling diode D1 provides a discharg...

Page 40: ...r command sources two load switches are implemented as identical circuits This would limit the current drawn from the outside providing both short circuit and overload protection and thus maintaining the internal logic supply lines safe Additionally TVS diodes are added for ESD protection External current consumption Both 5 V and 3 3 V internal logic supplies must be able of handling the self cons...

Page 41: ...es of both the load switch and the resistor the current would be limited to a minimum of 246 mA and a maximum of 315 mA with a typical value of 282 mA Thermal drifts are not considered in this calculation This approach provides a quite rugged overcurrent protection but it is very weak in front of overvoltage Any voltage over 6 5 V in the output might cause permanent damage to the load switch TVS w...

Page 42: ...g 400 W R1 R2 RMCF0402FT100K Stackpole 0402 Thick film resistor 100 kΩ 1 tolerance 1 16 W U1 U2 AP2553W6 7 Diodes Incorporated SOT 23 6 N 5 5 V self protected load switch adjustable current limit 7 2 5 Communications Motion Control Bus Everest CORE is interfaced by means of the proprietary Motion Control Bus protocol The physical layer required is similar to SPI working under 3 3 V levels and requ...

Page 43: ...ected to pin 26 of Everest CORE Interface connector HW_RESET Everest CORE Reset input To be connected to pin 38 of Everest CORE Interface connector GND_D Logic supply reference voltage To be connected to pins from 13 15 17 19 21 23 and 25 of Everest CORE Interface connector Design Notes MCB_SYNC1 and MCB_IRQ are used during boot up R1 and R2 ensure a proper boot up sequence Assuming that the drivi...

Page 44: ... V Logic supply HALL_IN_1 Digital hall inputs from motor HALL_IN_2 HALL_IN_3 HALL_1 To be connected to pins 17 19 and 21 of Everest CORE Feedback connector HALL_1 HALL_1 GND_D Logic supply reference voltage To be connected to pin 15 of Everest CORE Feedback connector Design Notes U1 is represented as 3 symbols A B and C but still a single component ...

Page 45: ... R5 RMCF0402FT1K00 Stackpole 0402 Thick film resistor 1 kΩ 1 tolerance 1 16 W R2 R4 R6 RMCF0402FT10K0 Stackpole 0402 Thick film resistor 10 kΩ 1 tolerance 1 16 W U1 74LVC3G17DP 125 NXP 8 TSSOP Non inverting triple Schmitt trigger buffer 24 mA output 1 65 V to 5 5 V supply Quadrature Incremental Encoder This circuit RS422 RS485 line receivers as hysteresis comparators Line receivers perform very go...

Page 46: ...pply DIG_ENC_A To be connected to pins 24 26 and 28 of Everest CORE Feedback connector to feed Digital Encoder 1 To be connected to pins 30 32 and 34 of Everest CORE Feedback connector to feed Digital Encoder 2 DIG_ENC_B DIG_ENC_Z DIG_ENC_A_P Incremental encoder channel A differential pair DIG_ENC_A_N DIG_ENC_B_P Incremental encoder channel B differential pair ...

Page 47: ...r and leave the negative unconnected It is mandatory that the encoder and the Everest CORE then share their reference voltage or Ground Bill of materials Designator Part Number Manufactur er Packag e Value Description C1 C2 C5 C8 GRM155R71C104KA 88D Murata 0402 Ceramic capacitor 100 nF 16 V X7R C3 C4 C6 C7 C9 C10 CC0402JRNPO9BN1 01 Yageo 0402 Ceramic capacitor 100 pF 50 V NP0 R1 R2 R6 R7 R8 R12 R1...

Page 48: ...C_DATA_N Data input differential pair to absolute encoder ABSENC_DATA_P ABSENC_CLK Clock signal from Everest CORE to be connected to pin 38 of Feedback connector or pin 50 of Interface connector ABSENC_DATA Data signal from Everest CORE to be connected to pin 40 of Feedback connector or pin 51 of Interface connector GND_D Logic supply reference voltage To be connected to pin 36 of Feedback connect...

Page 49: ... to read it properly In this case leave the negative terminal of the differential pair unconnected R4 pulls up the positive terminal for an extra robustness in front of a weak and noisy connection C1 and C4 are decoupling capacitors for U1 and U2 Bill of materials Designator Part Number Manufacturer Package Value Description C1 C4 GRM155R71C104KA88D Murata 0402 Ceramic capacitor 100 nF 16 V X7R C2...

Page 50: ...current Also brightness might substantially vary with this solution FAULT_SIGNAL carry a 3 3 V level Using a level shifter to 5 V and re dimensioning resistor R1 will notably improve brightness stability Bill of materials Designator Part Number Manufacturer Package Value Description R1 RC0402FR 07470RL Yageo 0402 Thick film resistor 470 Ω 1 tolerance 1 16 W R2 RMCF0402FT1K00 Stackpole 0402 Thick f...

Page 51: ...st approach would allow Everest CORE to reach its specified nominal phase current but it will not be possible to unplug it from the interface board On the other hand the second approach will be limited to the rated current of the contacts but allowing the Everest CORE to be unplugged if required Both strategies will require TH pads to hold the Everest CORE meaning that a full footprint for Everest...

Page 52: ...t the PCB component does include some critical information in various of its mechanical layers Mechanical layer 5 can be used as a positioning guide for the required mating and fixing elements Mechanical layer 10 contains the bounding boxes and designators for each component used to generate the Assembly Drawing 2D output If the Everest CORE is flipped from Top to Bottom layer this information sho...

Page 53: ...out advice can be found in Mechanical layer 15 Understand the lines as the limits for component placement outside or below the Everest CORE in such way that no component should cross them Footprint of mezzanine connectors Mechanical 5 includes the footprint of the 2 required mating mezzanine connectors It is not made out of rectangular shapes representing copper but actual numbered SM and TH pads ...

Page 54: ...ich can behave both as a victim or as an aggressor from the EMC point of view As an example do not lay the copper connected to the power pins towards the inside of the Everest CORE but towards the outside This would prevent the power signals from affecting sensitive circuits of the Everest CORE 7 3 3 Layout considerations The attached snippet includes the footprints of the mating and fixing compon...

Page 55: ...evel of sophistication in terms of PCB manufacturing technology but is sufficient to interface the Everest CORE thus entailing a cheaper cost However very dense designs might go for a less restrictive PCB Class specially when most of the signals in the mezzanine connectors are used Use of vias or microvias Although not specifically required designs where most of the signal pins are used at the sam...

Page 56: ... current of Everest CORE this would help minimising the number of layers required to carry the phase currents without causing considerable losses due to self heating However this might entail jumping from PCB Class 6 to Class 7 in some cases Consult your PCB manufacturer Also in very small designs where the phases copper self heating cannot be easily evacuated consider selecting FR 4 dielectrics w...

Page 57: ...imum clearance to Protective Earth chassis 0 5 mm Minimum distance between Signal conductors internal external layers 0 15 mm Minimum track width internal external layers 0 15 mm Minimum component body clearance 0 2 mm Minimum annular ring internal external layers 0 15 mm Minimum plated hole diameter 0 2 mm Hole to hole clearance 0 3 mm Paste mask expansion 0 mm Solder mask expansion 0 05 mm Minim...

Page 58: ...servotecnica com info servotecnica com Norway ELECTRO DRIVES AS www electro drives no firmapost electro drives no Portugal MECÂNICA MORDERNA www mecmod com pt vendas mecmod com Russia AVI SOLUTIONS www avi solutions com sales avi solutions com Singapore I MOTION www imotionasia com ivan imotionasia com South Korea SERVOSTAR www servostar co kr servo servostar co kr South Korea ALLTEK www alltek co...

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