Application Note
Electric Bike BLDC Hub Motor
Control Using the Z8FMC16100
MCU
AN026004-0413
Abstract
This application note describes a controller for a 200 W, 24 V Brushless DC (BLDC)
motor used to power an e-bike (i.e., electric bicycle). The design uses Zilog’s
Z8FMC16100 MCU and associated circuitry to implement motoring control, regenerative
braking, and fault protection.
Note: The source code file associated with this application note, AN0260-SC01.zip, is available
for download on zilog.com. This source code has been tested with version 5.0.0 of ZDS II
for Z8 Encore! XP MCUs. Subsequent releases of ZDS II may require you to modify the
code supplied with this application note.
Features
The main features of this high-torque motor control application include:
•
Hall sensor commutation
•
Motor speed measurement
•
Potentiometer-adjustable motor speed
•
Open-loop or closed-loop speed control for precise speed regulation
•
Protection logic for over-voltage, over-current, and thermal protection.
Discussion
The Z8FMC16100 MCU features a flexible Pulse Width Modulation (PWM) module with
three complementary pairs or six independent PWM outputs supporting dead-band operation and fault protection trip input. These features provide multiphase control capability
for a variety of motor types and ensure safe operation of the motor by providing pulse-bypulse or latched fast shutdown of the PWM pins during fault condition.
The Z8FMC16100 MCU features up to eight single-ended channels of 10-bit analog-todigital conversion (ADC), with a sample and hold circuit. It also features one operational
amplifier for current sampling and one comparator for over-current limiting or shutdown.
A high-speed ADC enables voltage and current sensing, while dual-edge interrupts and a
16-bit timer provide a Hall-effect sensor interface.
A full-duplex 9-bit UART provides serial, asynchronous communication and supports an
option for the Local Interconnect Network (LIN) serial communications protocol. The
AN026004-0413
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
LIN bus is a cost-efficient single Master, multiple Slave organization that supports speed
up to 20 kbps.
The Z8FMC16100 MCU has a rich set of peripherals and other features such as: additional
16-bit timer with capture/compare/PWM capability, SPI, and I2C Master/ Slave for serial
communication, and an internal precision oscillator.
The single-pin debugger and programming interface simplifies code development and
allows easy in-circuit programming.
A block diagram of the Z8FMC16100 MCU is shown in Figure 1.
12-Bit PWM
16-Bit Timer
Module for
Capture/
Motor Control Compare/PWM
Operational
Amplifier
Up to 16 KB
Flash
8-Channel
10-Bit ADC
512 B SRAM
20 MHz
eZ8 CPU
2
I C, SPI, and
UART with LIN
Watchdog
Timer
Comparator
VBO/POR
and Reset
Control
Single-Pin
Debugger
Internal
Precision
Oscillator
Interrupt Controller
17 General Purpose I/O Pins
Figure 1. Z8FMC16100 MCU Block Diagram
Braking and Regenerative Charging
In this e-bike application, the Z8FMC16100 MCU’s PWM registers are configured to
operate in a complementary PWM mode when applied to an inverter bridge that consists
of six MOSFETs. This complementary PWM mode allows for greater control of the ebike’s braking and regenerative charging process. The BLDC motor will effectively run in
either a motoring mode or a generative mode.
Generative Mode is achieved when the the applied operating voltage is less than the
BEMF voltage produced by the rotating motor. Motoring Mode is achieved when the
applied voltage is equal to or greater than the BEMF voltage produced by the rotating
motor. Varying the applied operating voltage can be accomplished by changing the duty
cycle for each phase in the inverter bridge.
For quicker braking, the lower MOSFET devices of the inverter bridge are turned on while
the upper MOSFETs are turned off, thereby quickly producing a negative current (i.e., a
negative torque) to stop the motor. To gain a regenerative charge, the upper MOSFETs are
AN026004-0413
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
turned on to allow current flow back to the battery, while the lower MOSFETs are turned
off.
Hardware Architecture
In a Brushed DC motor, commutation is controlled by brush position. In a BLDC motor,
however, commutation is controlled by the supporting circuitry. The rotor's position must
therefore be fed back to the supporting circuitry to enable proper commutation.
Two different techniques can be used to determine rotor position:
Hall Sensor-Based Commutation. In the Hall sensor technique, three Hall sensors are
placed inside the motor, spaced 120 degrees apart. Each Hall sensor provides either a High
or Low output based on the polarity of magnetic pole close to it. Rotor position is determined by analyzing the outputs of all three Hall sensors. Based on the output from hall
sensors, the voltages to the motor's three phases are switched.
The advantage of Hall sensor-based commutation is that the control algorithm is simple
and easy to understand. Hall sensor-based commutation can also be used to run the motor
at very low speeds. The disadvantages are that its implementation requires both separate
Hall sensors inside the motor housing and additional hardware for sensor interface.
Sensorless Commutation. In the sensorless commutation technique, the back-EMF
induced in the idle phase is used to determine the moment of commutation. When the
induced idle-phase back-EMF equals one-half of the DC bus voltage, commutation is
complete.
The advantage of sensorless commutation is that it makes the hardware design simpler. No
sensors or associated interface circuitry are required. The disadvantages are that it requires
a relatively complex control algorithm and, when the magnitude of induced back-EMF is
low, it does not support low motor speeds.
When a BLDC motor application requires high torque, when the motor is running at low
speed, or when the motor is moving from a standstill, the Hall sensor commutation technique is an appropriate choice. A motor used in an electric bicycle application, for example, requires high initial torque and is a perfect application for Hall sensor commutation.
Furthermore, two voltage application techniques can be applied, based on the configuration of the supply-to-motor windings:
Sinusoidal. Sinusoidal voltage is continuously applied to the three phases. Sinusoidal
voltage provides a smooth motor rotation and fewer ripples.
Trapezoidal. DC voltage is applied to two phases at a time, and the third phase remains
idle. Trapezoidal voltage is less complex to implement. The idle phase is generating the
BEMF from the rotating magnet that passes the unenergized idle phase and provides the
BEMF zero-crossing data.
How Hall Sensor Commutation Works
To better understand how Hall sensor commutation works, let's look at how it's implemented with a two-pole motor. Six different commutation states are required to turn the
rotor one revolution. The motor’s commutation states are shown in Figure 2.
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
Figure 2. Hall Sensor Commutation States for a 2-Pole Motor
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
Table 1 indicates the relationship between the Hall sensor output and phase switching operations shown in Figure 2.
Table 1. Relationship Between Hall Sensor Output and Phase Switching
State
Hall A
Hall B
Hall C
Phase B
Phase C
Phase A
1
0
1
1
0
+VDC
–VDC
2
0
0
1
+VDC
0
–VDC
3
1
0
1
+VDC
–VDC
0
4
0
1
0
0
–VDC
+VDC
5
1
1
0
–VDC
0
+VDC
6
1
0
0
–VDC
+VDC
0
Table 2 lists the rating of the motor used to develop this application.
Table 2. Motor Rating for Electric Bike BLDC Motor Control Application
Type of Motor
Linix BLDC
Power Rating
30 W
Speed
3200 RPM
Number of poles
6
Voltage
24 V
Additionally, the application uses a 3-amp High Rupturing Capacity (HRC) fuse.
AN026004-0413
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
Using the Z8FMC16100 MCU in an Electric Bike BLDC Motor
Controller
Figure 3 offers a visual overview of the electric bike BLDC motor controller. For more
details about hardware connections, see Appendix A. Schematics on page 12.
:&-#
6$#
07-(
07-,
0ROTECTION
,OGIC
07-(
07-
07-,
07-(
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0HASE
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"RIDGE
0H"
0H#
07-,
(EAT3INK4EMP
$#"US6OLT
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!$#
6REF
$#"US#URRENT
3PEED#OMMAND
#OMMUTATION
,OGIC
(ALL3ENSOR!
0ORT"
(ALL3ENSOR"
(ALL3ENSOR#
3PEED
#ALC
3IGNAL
#ONDITIONING
4IMER
Figure 3. Electric Bike BLDC Motor Controller Block Diagram
Hardware Architecture
The design involves running the BLDC motor in a closed loop or an open loop, with speed
as set by a potentiometer. As shown in the architecture diagram, the design generates
PWM voltage via the Z8FMC16100 MCU’s PWM module to run the BLDC motor.
After the motor is running, the states of the three Hall sensors change based on the rotor
position. Voltage to each of the three motor phases is switched based on the state of the
sensors (commutation). Hall sensor interrupts capture timer ticks every sixty degrees to
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
measure the rotor speed of the motor. Other peripheral functions can be used to protect the
system in case of overload, undervoltage, and overtemperature.
The hardware is described in the following sections.
Three-Phase Bridge MOSFET
The three-phase bridge MOSFET consists of six MOSFETs connected in bridge fashion
used to drive the three phases of the BLDC motor. The DC bus is maintained at 24 V,
which is same as voltage rating of BLDC motor. A separate Hi-Lo gate driver is used for
each high- and low-side MOSFET phase pair, making the hardware design simpler and
robust. The high-side MOSFET is driven by charging the bootstrap capacitor.
The DC bus voltage is monitored by reducing it to suitable value using a potential divider.
The DC bus current is monitored by putting a shunt in the DC return path. An NTC-type
temperature sensor is mounted on MOSFET heat sink, providing analog voltage output
proportional to temperature.
PWM Module
The Z8FMC16100 MCU contains a six-channel, 12-bit PWM module configured in this
application to run in Complementary Mode. The switching frequency is set to 20 KHz.
The output on the PWM outputs is controlled according to the inputs from the Hall sensors.
The inputs from the Hall sensors determine the sequence in which the three-phase bridge
MOSFET is switched. The Duty cycle of the PWM is directly proportional to the accelerator potentiometer input. The change in the duty cycle controls the current through the
motor winding, thereby controlling motor torque.
Commutation Logic
The Hall sensors are connected to ports PB0, PB1 and PB2 on the Z8FMC16100 MCU.
An interrupt is generated when the input state on any pin changes. An interrupt service
routine checks the state of all three pins and accordingly switches the voltage for the three
phases of the motor.
Trapezoidal commutation is used for this application to make implementation simple. In
this process of commutation, any two phases are connected across the DC bus by switching the top MOSFET of one phase and bottom MOSFET of another phase ON. The third
phase is left un-energized (both top and bottom MOSFET of that phase are switched
OFF).
Speed Measurement
The Hall sensor outputs are connected to to ports PB0, PB1 and PB2. One out of three Hall
sensors is used to capture the Timer0 ticks, which represent the actual Hall period for
closed loop calculations.
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
Closed Loop Speed Control
Closed-loop speed control is implemented using a PI loop, which works by reducing the
error between the speed set by the potentiometer and actual motor speed. The output of
this PI loop changes the duty cycle of the PWM module, thereby changing the average
voltage to the motor, and ultimately changing the power input. The PI loop adjusts the
speed at the same rate as the Hall frequency from one of three Hall sensors. In this application, Open Loop operation is selected in the software by default because any rider of the ebike will control the speed of the bike.
Protection Logic
The ADC module periodically checks DC bus voltage, DC bus current, and heat sink temperature. If these values go beyond the set limits, the motor is shut down. These checks are
timed by Timer0 interrupt.
Over-Current Hardware Protection
The Z8FMC16100 MCU has a built-in comparator that is used to shut down the PWM for
over-current protection. When the current exceeds the set threshold, a PWM Comparator
Fault is generated to turn OFF the PWM Module.
Software Implementation
During implementation of the software, the following actions are performed:
Initialization. Hardware modules are initialized for the following functions:
•
Switch from internal to external oscillator for system operation
•
Enable alternate function on respective pins for ADC, Comparator, UART, PA6 as
GPIO configured to drive LED
•
Configure Timer0 to run in Continuous Mode to capture the Hall period timing
•
Configure the comparator to shut down the PWM module when an overcurrent results
•
Enable the Op Amp to measure the DC bus current flowing to the motor
•
Configure the ADC to read analog values such as DC bus voltage, current, temperature,
and acceleration potentiometer (only one channel at a time)
•
Configure the PWM module for the individual mode of operation with a 20 kHz switching frequency, control output depending on the values in the PWMOUT Register, and
drive the PWMOUT as defaulted to a low off state at Power-On Reset and at any Reset
•
Configure the Reset/Fault0 pin functions as a Fault0 function
•
Write-protect Flash memory
•
Enable Open Loop operation (shown in the main.h file)
•
Hardware control of the application, with the UART disabled
AN026004-0413
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
Interrupt. The Port B interrupt controls commutation. The Hall sensor output is read on
pins PB0:2, the software performs its filtering operation, and the switching sequence of
the MOSFET is determined. The PWM timer interrupt is used to time periodically occurring tasks and for the background loop to read analog values from different channels and
average these values, update the LED indicator status, and update the read parameters on
the UART.
For a visual representation of the application, see Appendix B. Flowcharts on page 17.
Testing/Demonstrating the Application
This section presents a list of the equipment used and procedures observed to test this ebike application.
Equipment Used
Testing for this application was conducted using the following equipment:
•
Z8FMC16100 Series Motor Control Development Kit
•
Tektronix digital oscilloscope
•
Fluke multimeter
•
30 W BLDC motor
•
24 V 7 Ah battery
•
Tektronix power supply
System Configuration
The system requirements on your PC are as follows:
•
Windows 7 OS
•
ZDS II version 5.0.0 installed
•
Optically isolated USB smart cable for program download and debugging
Procedure
Observe the following steps to test the BLDC motor:
1. On the Zilog MC MDS Board, configure the following jumpers:
a. Shunt the 1–2 positions on J4, J5, and J6
b. Shunt J2 and J3
2. Set the R7 potentiometer on MC MDS Board (99C0987; contained in the
Z8FMC16100 Series Motor Control Development Kit) to the middle position to start
the motor.
3. Connect the following wires from the motor to the 3-Phase Motor Control Application
Board (contained in the Z8FMC16100 Series Motor Control Development Kit but not
shown in the schematic).
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
a. Connect the heavy-gauge blue wire to Motor Phase A (P1)
b. Connect the heavy-gauge green wire to Motor Phase B (P2)
c. Connect the heavy-gauge white wire to Motor Phase C (P3)
4. Connect the following wires from the motor to the MC MDS Board (contained in the
Z8FMC16100 Series Motor Control Development Kit but not shown in the schematic).
a. Connect the Hall Sensor-C light gauge blue wire to PB2 at J1 pin 6 with additional
added 680 pF ceramic capacitor to GND.
b. Connect the Hall Sensor-B light gauge green wire to PB1 at J1 pin 4 with additional added 680 pF ceramic capacitor to GND.
c. Connect the Hall Sensor-A light gauge white wire to PB0 at J1 pin 2 with additional added 680 pF ceramic capacitor to GND.
d. Connect the light gauge black wire (Sensor Power Ground) to GND at TP1.
e. Connect the light gauge red wire (Sensor Power VCC) to VCC (3.3V) at TP2.
5. Connect the oscilloscope across the motor terminals.
6. Connect the motor control board to the 24 V power supply.
7. Build the code on ZDS II v5.0.0 and download the code through USB smart cable.
8. Measure the performance of motor at different loads, for each speed setting of the
potentiometer.
9. Record the readings and carry out the process for each step in the test sequence.
Test Results
Laboratory performance test of BLDC motor is as follows:
1. Minimum motor speed: 800 RPM
2. Maximum motor speed: 3200 RPM
3. Power consumption: 6 W at 3200 RPM (no load)
4. Regenerative Current at 200 RPM: 350 mA
Future Implementation
The application discussed in this document covers the motoring and regenerative braking
features for a BLDC hub motor used in an electric bike. Further improvements can be
made to the design by adding the following features:
•
Controlled charging of SLA batteries by plugging to the AC Mains adaptor
•
Implementing ‘Torque-boost’ functionality (through a push-switch), which will give a
boost to motor performance
AN026004-0413
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
•
Utilizing LIN/UART communication to create a dashboard display of measured
parameters (speed, Battery voltage, Current, and Fault conditions)
References
The following supporting documents are available free for download from the Zilog website.
•
eZ8 CPU User Manual (UM0128)
•
Z8FMC16100 Series Product Specification (PS0246)
•
PID Motor Control with the Z8PE003 Application Note (AN0030)
•
Z8 Encore!-Based SLA Battery Charger Application Note (AN0223)
•
Sensorless Brushless DC Motor Control with Z8 Encore! MC Microcontrollers
(AN0226)
•
Z8 Encore! XP-Based BLDC Fan Control Application Note (AN0228)
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
Appendix A. Schematics
Figures 4 through 8 show schematic representations of each of the application’s key blocks.
3 PHASE POWER STAGE
P4
F1
+VDC
+BUS
+BUS
5A FUSE
Q3
Q1
GATE_AH
Q5
GATE_BH
GATE_CH
IRFZ48
IRFZ48
IRFZ48
P1
PHASE_A
R6
150k
+
C4
+
3300uF 50V
A
P2
PHASE_B
PHASE_B
C1
C2
B
GATE_AL
Q6
GATE_BL
IRFZ48
C3
0.1uF 50V
Q4
Q2
3300uF 50V
C
0.1uF 50V
0.1uF 50V
C5
P3
PHASE_C
GATE_CL
IRFZ48
IRFZ48
V+
R2
R5
10.00k
10.0k
CS+
10.0k
CS-
R1
0.100 OHM
P5
R3
GND
HEATSINK TEMP SENSOR
TH
R4
NTC 10k
TH
Title
3 PHASE MOTOR CONTROL APPLICATION BOARD
Size
A
Document Number
Rev
96C0960-001
B
Figure 4. Electric Bike BLDC Motor Controller Application Schematic, #1 of 5
AN026004-0413
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
GATE DRIVE
BEMF DIVIDERS
PHASE_A
PHASE_B
D1
+12V
C6
C7
10uF
0.1uF
BAV19
C8
C9
0.1uF
10uF
PHASE_C
U1
R10
150k
R8
150k
VA
VB
R7
10.00k
R9
10.00k
1
R12
150k
AH
2
AL
3
4
VC
VCC VB
8
HIN
HO
7
VS
6
COM LO
5
LIN
R13
22.1 GATE_AH
R14
22.1 GATE_AL
PHASE_A
IR2101
R11
10.00k
D2
+12V
C10
C11
10uF
0.1uF
BAV19
C12
C13
0.1uF
10uF
U2
1
BH
2
BL
3
4
VCC VB
8
HIN
HO
7
VS
6
COM LO
5
LIN
R15
22.1 GATE_BH
R16
22.1 GATE_BL
PHASE_B
IR2101
VCC_33V
12V SUPPLY
D3
+12V
C14
C15
10uF
0.1uF
BAV19
C16
C17
0.1uF
10uF
L1
D4
BAV19
+12V
U3
10uH
C18
1
VCC VB
8
CH
2
HIN
HO
7
CL
3
VS
6
COM LO
5
C19
C20
R20
86.6k
U4
10uF
5
4
SW
1
FB
3
GND
2
VIN
EN
10uF
4
68pF
LIN
R17
22.1 GATE_CH
R18
22.1 GATE_CL
PHASE_C
IR2101
R19
10.0k
Title
3 PHASE MOTOR CONTROL APPLICATION BOARD
TPS61041
Size
A
Date:
Document Number
Rev
B
96C0960-001
Wednesday June 08 2005
Sheet
2
of
3
Figure 5. Electric Bike BLDC Motor Controller Application Schematic, #2 of 5
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
UNUSED
POWER INTERFACE
JP1
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57
59
JP2
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
HEADER 30x2/SM
VA
VC
CSV+
VCC_33V
CH
BH
BL
VCC_33V
VCC_33V
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57
59
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
VB
CS+
TH
CL
AH
AL
HEADER 30x2/SM
Figure 6. Electric Bike BLDC Motor Controller Application Schematic, #3 of 5
AN026004-0413
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
100
JP2
D1
2
1
ANA0_M
ANA2_M
PA0_OPINN
ANA4
VCC_33V
ANA6
PWM2H
PA2_CINP
PWM1H
GND
16
15
14
13
12
11
10
9
Z8FMC16110_32
PWM1H
PWM0L
PWM0H
GND
XOUT
XIN
VDD
PA3/TXDE/SCL
Y1
3
1
3
C4
2
1
C5
20MHz
10K
D2
2
1
YEL
LED
PA4_RXD
PA5_TXD
PA6_CTS
100
D3
2
PA1_OP_CN
PA0_OPINN
8
7
6
5
4
3
2
1
AGND
AVCC
ANA0
ANA1
ANA2
C19
C18
0.01
0.01
C20
10K
R6
0
C26
R7 5K
10uF
2
PA6_CTS
1
VCC_33V
NC
NC
NC
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
ANA1_M
PA1_OP_CN
PB3_ANA3_OPOUT
ANA5
GND
PC0_T0OUT
NC
NC
GND
NC
PA7_COUT
PA5_TXD
NC
NC
NC
NC
GND
-DIS_232
-DIS_IRDA
NC
GND
NC
NC
C3
HEADER 30x2/SM
Connection between AG
should be done as close
to the pin 5,
AGND.
Connection between AVCC
should be done as close
to the pin 4,
AVCC.
R9
1000pF
JP1
ND and GND
as possible
and VCC_33V
as possible
GND
GND
49.9K
R23 10K
J4
HEADER 3
VREF
1
2
3
VCC_33V
LOCAL/ MDS
ANA2
C21
10K
10K
10K
R11
R12
R13
ANA2_M
J5
HEADER 3
100pF
C22
GND
100pF
ANA1_M
1
2
3
PC0_T0OUT
ANA7
PWM2L
VREF
PWM0H
PWM0L
GND
VCC_33V
R15
10K
-RESET
VCC_33V
ANA6
SPEE D 1K R24
0.01
NC
NC
NC
PA3_TXDE
R5
GRN
LED
R14
10K
PA6_CTS
PA4_RXD
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57
59
C6 12pF
ANA5
R10
0.1uF
100pF
VCC_33V
ANA4
PB3_ANA3_OPOUT
100
PA4_RXD
PA5_TXD
PA6_CTS
ANA7
ANA6
R8
R3
12.4K
NC
NC
NC
GND
PA1/OPINP/CINN
PA0/OPINN
VREF
AGND
AVDD
PB0/ANA0/T0IN0
PB1/ANA1/T0IN1
PB2/ANA2/T0IN2
25
26
27
28
29
30
31
32
22pF
2
22pF
R2
7.5K
C2
R4
3
0.01
17
18
19
20
21
22
23
24
PWM1L
PWM2H
PWM2L
PC0/T0OUT
DBG
RESET/FAULT0
PA7/FAULT1/T0OUT/COUT
PA2/CINP
0.01
PWM1H
PWM0L
PWM0H
GND
XOUT
XIN
VCC_33V
PA3_TXDE
C1
PA4/RXD
PA5/TXD
PA6/CTS/SDA
PB7/ANA7
PB6/ANA6
PB5/ANA5
PB4/ANA4/CINN
PB3/ANA3/OPOUT
C17
PWM1L
U1
1
-RESET
DBG
RED
C16
2
connector
R1
PWM1L
PWM2H
PWM2L
PC0_T0OUT
DBG
-RESET
PA7_COUT
PA2_CINP
VCC_33V
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57
59
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
VCC_33V
VCC_33V
GND
VCC_33V
GND
-RESET
ANA1
J1
ANA0_M
C23
SW SPDT
RUN/ST OP
C24
Z8FMC16 AND MDS
CONNECTORS
C25
ANA0
1
3
5
7
9
SW SPDT
HEADER 5X2
S2
1
2
3
S1
DIRECT ION
HEADER 30x2/SM
2
4
6
8
10
J6
HEADER 3
0.1uF 0.1uF 0.1uF
Figure 7. Electric Bike BLDC Motor Controller Application Schematic, #4 of 5
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
VCC_33V
P1
PWR JACK
+ C9
C10
0.1uF
100/10
GND
VI
VO
VCC_33V
2
VCC_33V
PA5_TXD
R16
R17
+ C13
change p inout
1
3
C14
680
C1-
3
CONSOLE
GND
P2
C11
0.1uF
C2+
C2-
PA5_TXD
13
T1IN
T1OUT
17
GND
12
T2IN
T2OUT
8
15
R1OUT
R1IN
16
10
R2OUT
R2IN
9
V-
7
TXD0
CTS0
RXD0
1
6
2
7
3
8
4
9
5
0
PA4_RXD
PA4_RXD
2
4
C7
0.1uF
V+
6
PA6_CTS
100/10
0.1uF
C1+
5
C12
0.1uF
U3
SPX2815AU-3.3
2
19
U2
C8
0.1uF
VCC_5V
VCC
2
3
1
DB9 Female
USER
LED
1
3.3 O K
EN
SHDN
18
1
20
GND
D4
GND
NC
NC
14
11
SP3222EBCA
VCC_33V
GND
R18
10K
14
U4A
14
74LVC04/SO
U4B
1
-DIS_232
2
7
74LVC04/SO
3
J2
4
1
2
7
GND
U4C
74LVC04/SO
5
C15
R19
VCC_33V
6
68
330nF
R20
U5
7
R21
10K
U4E
U4D
74LVC04/SO
74LVC04/SO
11
14
14
2R7
9
-DIS_IRDA
10
8
IRDA_SD
PA4_RXD
7
J3
7
1
2
GND
DIS I RDA
14
PA5_TXD
5
VCC
1
LEDA
2
TXD
4
SD
3
RXD
6
GND
T
GND
ZHX1810
0
14
DIS RS 232
GND
U4F
VCC_33V
7
TP1
R22
10K
1
2
3
4
5
12
13
1
2
3
4
5
74LVC04/SO
TP2
VCC_33V
GND
P3
1
3
5
POWER AND COMMUN ICATIONS
DBG
INTERF ACE
2
4
6
-RESET
DBG
-RESET
DBG
Header 3x2
Figure 8. Electric Bike BLDC Motor Controller Application Schematic, #5 of 5
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
Appendix B. Flowcharts
Figure 9 presents a simple flow chart of the main, timer interrupt and Port B interrupt routines for the electric bike BLDC motor controller application.
Start
Main()
Initialize MCU
peripherals
Capture 3 Hall
sensor binary
states
Obtain ADC result
for set-speed used
for open/closed
loop
Switch into next
commutation state
Yes
No
Hall interrupt?
Hall states = 3?
Yes
Timer0
rollover?
No
No
Capture Timer0
period and reset
Timer0
Yes
Hall period =
0xFFFF
Apply PI control
value to PWM
registers
Yes
Closed loop
selected?
No
Figure 9. Electric Bike BLDC Motor Controller Application Flowchart
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Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note
Customer Support
To share comments, get your technical questions answered, or report issues you may be
experiencing with our products, please visit Zilog’s Technical Support page at 
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To learn more about this product, find additional documentation, or to discover other facets about Zilog product offerings, please visit the Zilog Knowledge Base at http://
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This publication is subject to replacement by a later edition. To determine whether a later
edition exists, please visit the Zilog website at http://www.zilog.com.
Warning: DO NOT USE THIS PRODUCT IN LIFE SUPPORT SYSTEMS.
LIFE SUPPORT POLICY
ZILOG’S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE
SUPPORT DEVICES OR SYSTEMS WITHOUT THE EXPRESS PRIOR WRITTEN APPROVAL OF
THE PRESIDENT AND GENERAL COUNSEL OF ZILOG CORPORATION.
As used herein
Life support devices or systems are devices which (a) are intended for surgical implant into the body, or (b)
support or sustain life and whose failure to perform when properly used in accordance with instructions for
use provided in the labeling can be reasonably expected to result in a significant injury to the user. A
critical component is any component in a life support device or system whose failure to perform can be
reasonably expected to cause the failure of the life support device or system or to affect its safety or
effectiveness.
Document Disclaimer
©2013 Zilog, Inc. All rights reserved. Information in this publication concerning the devices, applications,
or technology described is intended to suggest possible uses and may be superseded. ZILOG, INC. DOES
NOT ASSUME LIABILITY FOR OR PROVIDE A REPRESENTATION OF ACCURACY OF THE
INFORMATION, DEVICES, OR TECHNOLOGY DESCRIBED IN THIS DOCUMENT. ZILOG ALSO
DOES NOT ASSUME LIABILITY FOR INTELLECTUAL PROPERTY INFRINGEMENT RELATED
IN ANY MANNER TO USE OF INFORMATION, DEVICES, OR TECHNOLOGY DESCRIBED
HEREIN OR OTHERWISE. The information contained within this document has been verified according
to the general principles of electrical and mechanical engineering.
Z8 Encore! MC is a trademark or registered trademark of Zilog, Inc. All other product or service names are
the property of their respective owners.
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