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Solo MINI_v2, User Manual

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SOLO MINI_v2 User Manual 

Part Number: SLM0322_4020 

 

 

 

 

www.solomotorcontrollers.com

  

May  2022 - Revision V_1.0.1 

 

Copyright © 2022, All right Reversed. SOLO motor controllers. 

 

14 

Cascade Control Architecture in SOLO MINI_v2 for DC Motors: 

 

 

 

Figure 2 - Control Architecture of SOLO MINI_v2 for DC Brushed Motors 

 
As can be seen in Figure 2, the main architecture of Motor Controlling for DC brushed motors in 
SOLO follows a very similar pattern to 3-phase Motors Controlling with FOC, however the 
architecture is generally simple with only one cascade loop of Torque, Speed and Position. 
Similar to 3-phase motors, for DC brushed Motors, SOLO offers both Sensor-less and Sensor-
based controls as well as Servo-Driving in case an Incremental Encoder is attached to the Motor, 
so the whole control strategy and tunings are identical to the 3-phase motors with minor 
differences on the processing methods. 
 

 

 

Summary of Contents for MINI_v2

Page 1: ...y measures to keep the applications safe from unforeseen behaviors Supply Voltage Range 6 40 VDC Peak Current 80A Continuous Current 20A Features Easy to use Drives and Controls DC BLDC PMSM EC coreless and ACIM motors Closed loop and Open loop controls Speed Torque and Position control Sensor based and sensorless control Four Quadrant Regenerative operation Automatic parameter Identification and ...

Page 2: ...solomotorcontrollers com May 2022 Revision V_1 0 1 Copyright 2022 All right Reversed SOLO motor controllers 2 Revision History Revision Date Changes Firmware version V1 0 0 30 09 2021 First Release 0x001B009 V1 0 1 12 05 2022 SOLO MINI_v2 updated 0x00BB00A ...

Page 3: ...hase Motors 13 Cascade Control Architecture in SOLO MINI_v2 for DC Motors 14 SOLO s Interactional Sections 15 Connectors and Sections 16 Section 1 Motor Output 16 Section 2 Power Up LED 16 Section 3 Supply Input 17 Section 4 and 5 Speed Controller Gains 18 Section 6 Control Mode Switch 19 Section 7 I O Port 21 Section 8 USB Connection 31 Section 9 Communication Port 32 Section 10 and 11 Functional...

Page 4: ...d Motors_ Closed loop Sensorless Mode 40 DC brushed Motors_ Open loop Sensorless Mode 41 Standalone Wiring Example No External Modules 42 Essential Wiring Example SOLO MINI_v2 Arduino UNO 43 Minimum Required Wirings in Digital Mode 44 USB Interface Wiring 44 UART Interface Wiring 45 CANopen Interface Wiring 46 Wiring with Incremental Encoders 47 Wiring with HALL Sensors 48 ...

Page 5: ...es DC Supply Voltage Range continuous VDC 8 to 37 DC Bus Overvoltage Limit VDC 40 DC Bus Undervoltage Limit VDC 6 Maximum Peak Output Current A 80 Maximum Continuous Output Current A 20 Maximum Continuous Output Power W 500 Maximum Peak Output Power W 800 Internal Bus Capacitance µF 880 Switching Frequency output PWM frequency kHz 8 to 80 The minimum recommended voltage for high current applicatio...

Page 6: ...ontrol VDC 0 3 3 5V Modes of Operation Torque Speed Position Motors supported DC BLDC PMSM EC Coreless ACIM Hardware Protections Reverse Polarity Bus over voltage Bus under voltage over current and over temperature Current Torque Loop sampling time µs Synched to PWM frequency Min 7 µs Current Torque Loop execution time µs 7 Speed controller Loop sampling time µs 500 Speed controller Loop execution...

Page 7: ... Reversed SOLO motor controllers 7 Thermal Specifications Description Units Values Board Temperature Range C 20 to 85 Heatsink base Temperature Range C 0 85 Cooling system Natural Convection Mechanical Specifications Description Units Values Size H x W x L mm 18 64 x 63 62 x 74 03 Weight with heatsink gr 69 Form Factor Wall Mount ...

Page 8: ...Number SLM0322_4020 www solomotorcontrollers com May 2022 Revision V_1 0 1 Copyright 2022 All right Reversed SOLO motor controllers 8 Mechanical Dimensions All the measurements are in millimeters Download the 3D step model from here ...

Page 9: ...y short times considering the effect of spikes and fast harmonics Section PIN Connector name Input Output Units Min Typical Max Absolute Max 2 Supply Input Input VDC 6 37 40 3 S T speed torque Input VDC 0 5 0 5 5 3 P F current limit power flux Input VDC 0 5 0 5 5 3 DIR Direction control Input VDC 0 5 0 5 5 3 5V External supply Output VDC 4 95 5 0 5 2 8 CHA Encoder HALL_A Input VDC 0 5 0 5 5 8 CHB ...

Page 10: ...ith CANopen software layer which is called Digital Mode Control This will give a high flexibility in terms of system setup to the users and they can choose the best way to wire up their systems using SOLO The main features of SOLO MINI_v2 are listed as below Wide input voltage supply range from 8V to 40V The continuous output current of 20A Max Current of 80A Capable of controlling DC BLDC PMSM an...

Page 11: ...SOLO MINI_v2 User Manual Part Number SLM0322_4020 www solomotorcontrollers com May 2022 Revision V_1 0 1 Copyright 2022 All right Reversed SOLO motor controllers 11 Functional Block Diagram ...

Page 12: ...rrent Controller too this controller will try to stabilize the required torque current in the motor to make the whole system capable of overcoming the dynamics changes in the load 2 The Speed Controller The Speed Controller comes behind the Torque Controller it is slower than the Torque controller at least around tenfold and it basically tries to fix the Speed on a desired value this controller wi...

Page 13: ...is necessary to control the current inside of the motor and for Torque Controlling and it s measured internally by SOLO the accuracy of current measurement is 16mA in SOLO MINI_v2 2 Speed Feedback This feedback is either measured using the sensors mounted on the motor Encoders Halls or it s estimated by the Nonlinear observer in sensorless modes and it s used for Speed Controlling purposes 3 Posit...

Page 14: ...ture of Motor Controlling for DC brushed motors in SOLO follows a very similar pattern to 3 phase Motors Controlling with FOC however the architecture is generally simple with only one cascade loop of Torque Speed and Position Similar to 3 phase motors for DC brushed Motors SOLO offers both Sensor less and Sensor based controls as well as Servo Driving in case an Incremental Encoder is attached to...

Page 15: ...ctions SOLO MINI_v2 can be decomposed into 11 main interactional sections as shown in Figure 3 below all the sections are explained in detail and their electrical and maximum ratings are mentioned later in this user manual the user has to make sure that they don t exceed those maximum ratings to avoid damaging themselves or SOLO MINI_v2 unit Figure 3 SOLO MINI_v2 s interactional sections ...

Page 16: ...nnector of SOLO should be connected to the Motors wires You can find out more about how to connect them by looking at the Minimum Required Wirings part but in general for 3 phase motors the A B C pins should get connected to the 3 phase wires of the motor and for DC brushed motors only B and C pins are required to be connected to the motor Section 2 Power Up LED section Name Descriptions Notes I O...

Page 17: ...tage Input 2 Negative Voltage Input Ground Description This is the Power Supply input of SOLO and it can be supplied with any input voltages from 8 to 37 volts in continuous mode depending on the voltage rating of the Motor Connected at the output The max rating for supply input is 40V in transient mode meaning that SOLO will go into over voltage protection mode in case the supply or BUS voltage r...

Page 18: ...how fast your motor should react and reach the speed you asked so if you increase this value your motor will be more reactive but too much of this gain might make vibrations so you need to tune it enough Also another effect of this gain will be how harshly the controller here SOLO should react to the variation of the load on the shaft of the motor to keep the speed constant It s not always good to...

Page 19: ...s shown below Selection of this mode will affect both Analogue and Digital commanding modes and to use SOLO with its best performance it is recommended to use it in Closed loop mode as Open loop mode is mainly good for experimental purposes or applications that don t have any load variations on the shaft of the Motor Operation in Closed loop Mode Operation in Open loop Mode By Going from Openloop ...

Page 20: ...r the voltage the lower will be the allowed current into the motor so if this is the first time you are going to identify your motor parameters and going to closed loop mode make sure the P F input has no voltage on it you can leave it open or apply 0v or 0 duty cycle to it and keeping the system in closed loop mode you can leave the switch on closed loop C L forever even after turning the whole s...

Page 21: ...nd 8 DF DFU Mode Puts the device into Firmware Upgrade Mode I 9 S T Speed or Torque reference used in Analogue Mode I 10 5V 5V 1A output for external modules O 11 P F Current Limit Power or Flux reference used in Analogue Mode I 12 EA Channel A of the Encoder or Hall position sensors I 13 DIR Direction of rotation of the motor used in Analogue Mode I 14 EB Channel B of the Encoder or Hall position...

Page 22: ...e left open it s also possible to apply 5V or 3 3V to these Pins instead of leaving them open in case you want to control the Motor Type selection externally by a module Across each of the M1 and M2 there is a Ground pin GR and they provide the possibility of placing a Jumper between M1 or M2 to the GR pins in front of them to apply 0V logic or leaving them open in case of having no external modul...

Page 23: ...tocols and it has a default value of 1 to know more about it please refer to USB UART or CANopen manuals By selecting each motor type the switching frequency of SOLO at the output will be adapted to what has been mentioned in the table above These are default values and you can overwrite them using Digital commanding like by USB UART or CANopen by setting them digitally to any value from 8kHz to 8...

Page 24: ...ontrolling Speed or Torque of the Motor connected to SOLO depending on the selected Mode Torque or Speed on FN pin and the Position of the Control Mode switch shown in section 6 Closed loop or Open loop Operation the Analogue voltage or the duty cycle of PWM pulse applied at this input in either of the conditions will be treated as a desired reference of the user based on following situations Mode...

Page 25: ...this pin it will keep your motor s speed at 0 RPM and at the same time by applying 100 duty cycle or 5V Analogue input SOLO will force your motor to go to the maximum speed based on the Motor s type as below of course your motor should be able to reach to that speed otherwise it will stay at its nominal speed even if you keep increasing the duty cycle Motor code Motor Name Maximum Speed in Closed ...

Page 26: ...ormula The Normal BLDC motor speed RPM 5 0 the voltage at S T input 5 0 8000 ASRDC To have accurate motors speed measurements for 3 phase motors you need to set the number of Poles of your motor using the SOLO Motion Terminal or by using USB or UART or CANopen interfaces the default value for the number of poles in SOLO is set at 8 If you don t change this value SOLO will still function but you mi...

Page 27: ...s 5V it will stop the current floating to the motor current Limit at zero and if this pin is left open it will allow up to 32A floating into your Motor so any value between these will define the value of current limit You can calculate the current limit value based on following formulas In case of using PWM The current Limit value 100 duty cycle precentage of PWM at P F input 100 32 0 In case of u...

Page 28: ...or C C W direction 6 DFU Mode selection for upgrading the firmware DF Pin This pin should never be at logic Low except the moments you want to upgrade the firmware of SOLO in that case you need to do the followings a Turn OFF SOLO b Put the DF pin at logic Low put a jumper between DF and GR pin in front of it c Turn ON SOLO d Upgrade the Firmware e Put back the DF pin in Logic High leave it Open f...

Page 29: ...sence of Index pulse is not needed To learn about how to Setup and calibrate your Incremental Encoders for SOLO MINI_v2 please visit this page on our website To learn about how to Setup and calibrate your HALL sensors for SOLO MINI_v2 please visit this page on our website 9 UART TX and UART RX pins TX and RX Pins The UART RX and TX pins are accessible through RX and TX pins on the I O connector th...

Page 30: ...SOLO MINI_v2 User Manual Part Number SLM0322_4020 www solomotorcontrollers com May 2022 Revision V_1 0 1 Copyright 2022 All right Reversed SOLO motor controllers 30 ...

Page 31: ...ce Firmware upgrader Description This is the micro_USB 2 connector of SOLO which is used for sending and receiving digital packets and commands as well as upgrading the firmware in Commanding mode this USB will be a virtual COM port VCP capable of putting SOLO into digital control mode and functioning in standalone fashion with only 1 USB cable and the Motor connected at the output You can downloa...

Page 32: ...und 4 GND SOLO s Ground 5 5V 500mA 5V external supply O 7 GND SOLO s Ground 9 CANL CAN Low Bus Output ISO 11898 11 CANH CAN High Bus Output ISO 11898 13 CAN_RX CAN protocol receiver input I 15 CAN_TX CAN protocol transmitter output O 17 UART_TX UART protocol transmitter output O 19 UART_RX UART protocol transmitter input I 20 GND SOLO s Ground Description This is the port that gives you the access...

Page 33: ... CANbus or CANopen networks as they are coming out of the DSP directly without any CAN transceiver in between to use CANbus for CANopen networks the user must use the CANH and CANL pins provided in Section 13 below The communication port provides you two supply voltages of 3 3V and 5V with the main Ground reference of SOLO so you can use them to feed external modules with the mentioned current lim...

Page 34: ...o LEDs on the bottom right side of SOLO which are named as E1 and E2 and each of them has a functionality as below E2 This is the status LED indicator after the device startup in case of having a safe boot up with no errors like over current over voltage etc it will start blinking and remains in the blinking state as long as no error occurred E1 This is the Error indicator and in case of an error ...

Page 35: ...om the I O port by using M1 and M2 pins and if you set it using Motion Terminal or you send the data packet through UART USB or CANOpen it will not change the Motor type unless you go to Digital Mode before The main reason that Analogue Mode exists on SOLO is to eliminate the need for the users to set a special parameter through a software and to minimize the interfacing effort to SOLO for simple ...

Page 36: ...M voltages depending on the type of the electrical motors connected are shown later in this chapter Wiring Legend Shape Description Input Positive of the DC supply Input Negative or Return of the DC supply Fuse the value can be selected based on the system requirements Line carrying pulses with PWM fixed frequency above 5kHz Line carrying Pure Analogue voltage Line carrying ON OFF type of signals ...

Page 37: ...e To put SOLO in Closed loop Mode the Control Mode Switch should be on C L as also shown in the image above In sensorless closed loop mode the order of the connection of Motor wires to A B C output is not important and it will only affect the Direction of rotation which you can set using DIR input To select the Motor Type in Analogue mode the Pins M1 and M2 should be used as explained in the I O p...

Page 38: ...p Mode To put SOLO in Open loop Mode the Control Mode Switch should be on O L as also shown in the image above In sensorless Open loop mode the order of the connection of Motor wires to A B C output is not important and it will only affect the Direction of rotation which you can set using DIR input To select the Motor Type in Analogue mode the Pins M1 and M2 should be used as explained in the I O ...

Page 39: ...de To put SOLO in Closed loop Mode the Control Mode Switch should be on C L as also shown in the image above In sensorless closed loop mode the order of the connection of Motor wires to A B C output is not important and it will only affect the Direction of rotation which you can set using DIR input To select the Motor Type in Analogue mode the Pins M1 and M2 should be used as explained in the I O ...

Page 40: ... To put SOLO in Closed loop Mode the Control Mode Switch should be on C L as also shown in the image above In sensorless closed loop mode the order of the connection of Motor wires to B and C output is not important and it will only affect the Direction of rotation which you can set using DIR input To select the Motor Type in Analogue mode the Pins M1 and M2 should be used as explained in the I O ...

Page 41: ...e To put SOLO in Open loop Mode the Control Mode Switch should be on O L as also shown in the image above In sensorless Open loop mode the order of the connection of Motor wires to B and C output is not important and it will only affect the Direction of rotation which you can set using DIR input To select the Motor Type in Analogue mode the Pins M1 and M2 should be used as explained in the I O por...

Page 42: ...se Not that The current Limit Potentiometer is not mandatory to use and if you leave the P F input open the current Limit will be automatically set at 32A This input in closed loop mode acts as if the voltage applied to this pin is 5V it will stop the current floating to the motor resulting in free wheeling Current Limit at zero and if this pin is left open it will allow up to 32A floating into yo...

Page 43: ...e seen Arduino has been directly powered up by SOLO depending on the Arduino models the user can commit the USB of the Arduino at the same time the most important point in power conenction is to make sure the GND pin of SOLO has been connected to the GND of your Arduino or other modules at least in a single point To put SOLO in Closed loop Mode the Control Mode Switch should be on C L The Motor ty...

Page 44: ...er types of motors USB Interface Wiring By using USB connection you have the access to the simplest form of wiring of SOLO to be commanded using only the USB cable thanks to the digital control that it offers in this mode the only thing you will need is a Micro USB cable that makes SOLO able to communicate with a local PC or controller through USB communication as a Virtual COM Port in such a setu...

Page 45: ...essible both through the I O Port or through the Communication Port in SOLO MINI_v2 models the UART_RX and UART_TX lines are 5V tolerant and they can be fed both by signals leveled at 3 3V or 5V To put SOLO in Closed loop Mode the Control Mode Switch should be on C L and subsequently for SOLO to operate in Open loop Mode the Control Mode Switch must be on O L regardless of being in Analogue or Dig...

Page 46: ...n be accessed both through the I O port or the Communication Port using CANH and CANL pins that are also shown with CH and CL on the I O port To put SOLO in Closed loop Mode the Control Mode Switch should be on C L and subsequently for SOLO to operate in Open loop Mode the Control Mode Switch must be on O L regardless of being in Analogue or Digital Command Mode CAN_TX and CAN_RX pins are CAN outp...

Page 47: ...ontrolling Torque Speed and Position of your Motor once using Incremental Encoders you need to make sure you apply the correct setup followed by one time calibration of the system to learn about the process please visit this page on our website To put SOLO in Closed loop Mode the Control Mode Switch should be on C L and subsequently for SOLO to operate in Open loop Mode the Control Mode Switch mus...

Page 48: ...se the accuracy of Speed and Torque controlling Once using HALL sensors you need to make sure you apply the correct setup followed by one time calibration of the system to learn about the process please visit this page on our website To put SOLO in Closed loop Mode the Control Mode Switch should be on C L and subsequently for SOLO to operate in Open loop Mode the Control Mode Switch must be on O L...

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