Using the TMS320C24X
DSP Controller for Optimal
Digital Control
APPLICATION REPORT: SPRA295
Authors: Kai M. Chung
Astro Wu
DSP Applications
Tresna Hidajat
DSP Strategic Marketing
Texas Instruments Taiwan Limited
Digital Signal Processing Solutions
January 1998
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[email protected] Contents
Abstract ........................................................................................................................... 7
Product Support on the World Wide Web .................................................................... 8
Introduction..................................................................................................................... 9
Analog Vs Digital Control Systems ............................................................................. 9
Benefits of Microcontrollers ........................................................................................ 9
Benefits of DSP-Based Control ................................................................................ 10
Control System ............................................................................................................. 12
Digital Controller Requirements.................................................................................. 13
Processor Requirements ............................................................................................. 14
TI TMS320C24x DSP Family – the Optimal Digital Control System Solution .......... 15
Applications .................................................................................................................. 18
Summary ....................................................................................................................... 21
References .................................................................................................................... 21
Figures
Figure 1. Typical Control System..................................................................................... 12
Figure 2. Block Diagram of a Digital Control System....................................................... 12
Figure 3. TMS320C240 DSP Architecture....................................................................... 15
Figure 4. TMS320C240 Event Manager Module ............................................................. 16
Figure 5. TMS320C240 Analog-to-Digital Converter Module .......................................... 17
Using the TMS320C24X DSP
Controller for Optimal Digital Control
Abstract
Although traditional microcontrollers include the necessary
peripherals to provide solutions for digital control applications,
they lack both the performance and architecture needed to
perform real-time, math-intensive, advanced control algorithms at
a desired bandwidth.
This application report describes the features of the Texas
Instruments (TI™) TMS320C24x digital signal processor (DSP), a
low cost, single chip solution for optimal digital control system
applications. This solution is a tribute to the integration of not only
a powerful DSP core, but also to its specialized digital control
circuit (known as the event manager) and a comprehensive set of
desired peripherals.
Because of the high bandwidth signal processing ability of the
DSP, this DSP controller can help designers easily achieve a
robust, precise, adaptive, and sensorless digital control system.
Using the TMS320C24X DSP Controller for Optimal Digital Control 7
SPRA295
Product Support on the World Wide Web
Our World Wide Web site at www.ti.com contains the most up to
date product information, revisions, and additions. Users
registering with TI&ME can build custom information pages and
receive new product updates automatically via email.
8 Using the TMS320C24X DSP Controller for Optimal Digital Control
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Introduction
Saving energy has become a key concern because of the
continuing increase in energy usage. Increased efficiency reduces
capital spending by utility companies building additional power
plants, which in turn reduces utility costs for customers. To remain
competitive, power plant administrators are pressured not only to
reduce costs imposed by governments and power plant lobbies,
but also to answer to power consumption reduction and EMI
radiation reduction issues.
These constraining factors result in the need for enhanced
algorithms. In addition to system cost reduction, DSP technology
makes digital control more practical and also offers a high level of
performance.
The TI TMS320C240 DSP is part of a new generation of
processors addressing digital motor control and power conversion
optimization. The TMS320C240 is specifically designed for the
digital motor control and power conversion segments, combining a
16 bit fixed-point DSP core with microcontroller peripherals in a
single chip solution.
Analog Vs Digital Control Systems
Early solid state controls consisted of hardwired analog networks
built around operational amplifiers. Analog controls offer two
distinct advantages over digital systems:
q Higher speed control by processing input data in real time
q Higher resolution over wider bandwidths because of infinite
sampling rates
However, there are several drawbacks to analog systems:
q Aging and temperature can cause component variations,
which in turn causes the system to need regular adjustment.
q Analog systems have more physical parts than digital systems,
which reduces reliability and makes analog systems more
difficult to design (component tolerance issues).
q Upgrades are difficult because the design is hardwired.
Benefits of Microcontrollers
q Drift is eliminated since most functions are performed digitally.
q Upgrades are easily made in software.
Using the TMS320C24X DSP Controller for Optimal Digital Control 9
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q Part count is reduced because the microcontroller can handle
several functions on-chip. Microcontrollers are good for
systems that do not require high speed or precision.
Benefits of DSP-Based Control
The TMS320C24x DSP includes the same advantages as the
microcontroller but also offers higher speed, higher resolution, and
capabilities to implement the math-intensive algorithms to lower
the system cost. The high speed is attributable mainly to the dual
bus of the Harvard architecture as well as single-cycle
multiplication and addition instructions. One bus is used for data
and the other is used for program instructions. This saves time
because each is utilized simultaneously. Traditionally, cost has
been a potential disadvantage of the DSP solution, but this aspect
has diminished with the continuing decline of DSP costs.
DSP controllers enable enhanced, real-time algorithms as well as
sensorless control. The combination reduces the number of
components and optimizes the design of silicon to achieve a
system cost reduction.
DSPs are capable of processing data at much faster rates than
microcontrollers. For example, the speed of the DSP allows it to
estimate motor velocity, a task accomplished by a tachometer in
analog and microcontroller systems.
DSP-based controls offer the following additional benefits:
q Sharp-cutoff notch filters that eliminate narrow-band
mechanical resonance. Notch filters remove energy that would
otherwise excite resonant modes and possibly make the
system unstable.
q Diagnostic monitoring achieved by the fast Fourier transform
(FFT) of spectrum analysis. By observing the frequency
spectrum of mechanical vibrations, failure modes can be
predicted in early stages.
q Adaptive control by having the speed to monitor and control
the system concurrently. A dynamic control algorithm adapts
itself in real time to variations in system behavior.
For example, FFT data can be used to tune notch filters to
track and eliminate vibrational modes as they vary with system
speed, weight, balance, or other parameters.
q System cost reduction by an efficient control in all speed
ranges, implying right dimensioning of power device circuits
q High level algorithms from reduced torque ripple, which results
in lower vibration and longer life
10 Using the TMS320C24X DSP Controller for Optimal Digital Control
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q Reduced harmonics using enhanced algorithms to meet easier
requirements and reduce filter costs
q Remove speed or position sensors by implementing
sensorless algorithms
q Reduce the number of look-up tables, which reduces the
amount of memory needed
q Real-time generation of smooth, near-optimal reference
profiles and move trajectories, which results in better-
performance
q Control power switching inverters and generate high-resolution
PWM outputs
q Single chip control system
Using the TMS320C24X DSP Controller for Optimal Digital Control 11
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Control System
In general, a control system consists of a plant (or process),
controller, sensors, and actuators. A typical control system is
shown in Figure 1. To achieve the desired output, the control
system commands or regulates the plant, thus allowing the output
to behave as expected.
Figure 1. Typical Control System
Controller Actuator Process/Plant
Sensor
As the performance and reliability of microprocessors increase,
digital control system approaches have become more attractive
for designers attempting to build their own solutions. The digital
control system block diagram is shown in Figure 2.
Figure 2. Block Diagram of a Digital Control System
101 000
011 011
110 110
S/H
&
Digital
D/A Hold Actuator Plant
+ A/D Controller
-
Sensor
12 Using the TMS320C24X DSP Controller for Optimal Digital Control
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Digital Controller Requirements
The following list highlights the digital controller requirements.
q Calculations powerful enough to implement advanced and
math-intensive control algorithms, such as
M N
y( t ) = ∑ a( m ) y( t − m ) + ∑ b( n ) x ( t − n )
m=0 n=0
q Fast response to events to obtain input signals and to
unexpected events to secure the system
q Accurate resolution to minimize quantization errors; therefore,
a precise digital control system is offered
q High sampling rate to avoid aliasing introduced by sampling
effects
q Required peripherals to reduce CPU overhead and system
cost
Using the TMS320C24X DSP Controller for Optimal Digital Control 13
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Processor Requirements
The following list highlights the processor requirements.
q Strong calculating power for advanced and math-intensive
control algorithms
q Capability to support large word lengths for required resolution
and dynamic range
q Small interrupt latency and fast branch operations capabilities
to facilitate quick response to events, including unexpected
events
q High-MIPS CPU to increase the range of the sampling
frequency
q Integrate the application-specific peripherals with the
processor, such as timers, A/D converters, PWM generators,
and communication interfaces. Hence, CPU overhead and
total system costs are reduced.
14 Using the TMS320C24X DSP Controller for Optimal Digital Control
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TI TMS320C24x DSP Family – the Optimal Digital Control
System Solution
The TMS320C24x, the first single-chip DSP solution for the digital
control system market, integrates the TI 16 bit, fixed-point
TMS320C2xLP DSP core with several microcontroller peripherals.
The DSP core itself has up to 20 MIPS (50 ns cycle time) speed
and can perform the useful multiply/accumulate instruction in a
single cycle.
The TMS320C240 has a 544-word data/program RAM and 16K-
word program ROM. Although the TMS320F240 has the same
amount of memory, the program ROM is Flash type. The totally
external memory address reach of this family is 224K words (64K
data, 64K program, 64K I/O, and 32K global memory). The
architecture of the TMS320C240 DSP is shown in Figure 3.
The full set of powerful peripherals include an optimized event
manager, two sets of analog-to-digital (A/D) converters on-chip, a
watchdog timer, a serial communication interface (SCI), a serial
peripheral interface (SPI), and four I/O ports.
Figure 3. TMS320C240 DSP Architecture
Data RAM Program ROM/FLASH
544 word 16 Kword 3 Timers
9 Compares
12 PWM Outputs
Program / Data / I/O Buses Dead Band Logic
4 Input Captures
QEP
16-Bit T Register
C2xLP Core 16 x 16 Multiply
Four 8-Bit I/O Ports
16-Bit Barrel Shifter (L) 32-Bit P Register
Shift L (0,1,4,-6) Watchdog Timer
32-Bit ALU
32-Bit Accumulator SPI
Shift L (0-7)
SCI
8 Auxiliary Registers
8 Level Hardware Stack A/D Converters
Repeat Count 8 x 10-Bit - ADC1
2 Status Registers 8 x 10-Bit - ADC2
Using the TMS320C24X DSP Controller for Optimal Digital Control 15
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The event manager module is shown in Figure 4. Features include
three up/down timers and nine comparators that can create up to
12 PWM generation capabilities when coupled with flexible
waveform generation logic. A space-vector PWM state machine
implements an optimized scheme for switching power transistors,
yielding longer transistor life span and lower power consumption.
A dead-band generation unit helps protect power transistors. In
addition, the event manager integrates four capture inputs, two of
which can serve as direct inputs for optical-encoder quadrature
pulses. In all, these features represent a state-of-art solution for
flexible PWM generation and system control.
Figure 4. TMS320C240 Event Manager Module
DSP Memory
( ROM, RAM, Flash )
GP Timer1 Output
Logic GP Timer Compare 1
GP Timer compare Unit
Program. Output Logic CMP1/PWM1
Compare Unit 1 PPG Deadband Circuit CMP2/PWM2
Program. Output Logic
Compare Unit 2 PPG CMP3/PWM3
Deadband Circuit CMP4/PWM4
Compare Unit 3 PPG Program. Output Logic CMP5/PWM5
Deadband Circuit CMP6/PWM6
GP Timer2
Output
Logic GP Timer Compare 2
GP Timer compare Unit
MUX
Simple Compare 1 SCMP1/SPWM1
Output
Simple Compare 2 Logic SCMP2/SPWM2
Unit
Simple Compare 3 SCMP3/SPWM3
GP Timer3
Output
Logic GP Timer Compare 3
GP Timer compare Unit
MUX
Capture Unit 1 QEP 1
CAP1/QEP1
Capture Unit 2 QEP2 CAP2/QEP2
Capture Unit 3 CAP3
ADC 1 MUX 8 ADC 1 Inputs
Capture Unit 4 CAP4
ADC 2 MUX 8 ADC2 Inputs
Two sets of 10-bit A/D converters are available on-chip. As shown
in Figure 5, each of the A/D converters provides 8-channel inputs.
The two sample-and-holds allow parallel and simultaneous
sampling and conversion. A new conversion starts immediately
after the previous conversion is completed. A/D converters can
begin conversion by software instruction, external signal transition
on a device pin, or an event manager event. The conversion time
is 6.6 µs.
16 Using the TMS320C24X DSP Controller for Optimal Digital Control
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Figure 5. TMS320C240 Analog-to-Digital Converter Module
A/D Converter
8 Inputs 8/1 Data Register 1
Sample and Hold 1
Multiplexer 1 10-Bit 5V 6.6 us 2 Level Deep FIFO
ADC1
A/D Converter
8 Inputs 8/1 Data Register 2
Sample and Hold 2
Multiplexer 2 10-Bit 5V 6.6 us 2 Level Deep FIFO
ADC2
Using the TMS320C24X DSP Controller for Optimal Digital Control 17
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Applications
DSPs are used for servo control of the actuator that drives the
read/write head of disk drives. Data is read from the disk at a very
high rate with sampling rates of up to 50 kHz. In addition to the
compensator, DSPs can implement notch filters to attenuate
undesirable frequencies that cause mechanical resonance or
vibrations.
In AC servo drives, DSPs are used for vector control of AC
motors. AC drives have complex control structures because of the
cross coupling of the three-phase currents. Vector rotation
techniques transform three-phase axes into rotating two-phase d-
q axes. This two-phase rotation technique greatly simplifies the
analysis, making it equivalent to analyzing field-wound DC motors.
In UPSs and power converters, DSPs are used for PWM
generation as well as power factor correction and harmonic
elimination. Advanced mathematical techniques can be used to
control the firing angles of the inverters, creating low-harmonic
PWM with unity power factors.
Three classical motors are among the existing electric motors on
the market:
q DC with commutators (wound field)
q Synchronous AC motor
q Asynchronous AC motor
When properly controlled, these classical motors produce
constant instantaneous torque (very little torque ripple) and
operate from pure DC or AC sine wave supplies. Unlike DC
motors, the use of which is levelling off and even declining each
year, the use of AC motors is increasing each year. A couple of
reasons for this increase are possible: AC motors cost less than
DC motors and, AC motors can be controlled more easily using
digital control (especially DSPs).
For example, brushless permanent magnet synchronous motors
(PMSM) include a vector control approach in which matrix and
vectors represent the control quantities. Using a MAC calculation
unit included with the TMS320C24x DSP provides the following
advantages:
q Full motor torque capability at low speed
q Better dynamic behavior
18 Using the TMS320C24X DSP Controller for Optimal Digital Control
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q Higher efficiency for each operation point in a wide speed
range
q Decoupled control of torque and flux
q Short term overload capability
q Four quadrant operation
Sensoring or sensorless algorithms can also be implemented with
DSPs. The most common way to sense motor speed on the shaft
is to use an incremental encoder. The TMS320C240 includes a
module, the quadrature encoder pulse (QEP), that handles the
situation perfectly, calculating the speed and direction of the
rotation using only two digital inputs and a 16- or 32-bit internal
timer register.
In some applications emphasising efficiency, cost, reliability, and
mechanics, it is not possible to use a speed, position, or Hall
(commutation signals) sensor. In such situations, the necessary
information can be derived from dynamic modelling applications
such as sliding mode observer or Kalman filtering. In PMSM
applications, a Kalman filter can be used for the estimation of
speed and rotor position with only measurements of the motor
voltages and currents.
DSPs also benefit automotive applications ranging from
engine/transmission control, active suspension control, adaptive
ride control, anti-lock brakes, and traction control. The
performance of the current electronic engine control in power-train
control applications can be improved by a closed loop control
system. The system incorporates a DSP with sensors, such as in-
cylinder pressure sensors, to control the precise operating status
of each cylinder at every cycle.
The DSP in the system performs engine pressure waveform
analysis and determines the best spark timing, firing angles, and
optimal air/fuel ratios. Closed loop external turbulence, such as
aging and wearing, maintain optimum engine performance and
fuel efficiency.
Vehicle control applications benefit from active suspension that
can help improve ride performance by introducing variable
damping ratios into dampers. The TMS320C24x can also consider
body dynamics, such as pitch, heave, and roll to control hydraulic
actuators independently and dynamically to counter external
forces and car attitude changes.
Using the TMS320C24X DSP Controller for Optimal Digital Control 19
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DSPs perform control algorithms with system parameters
adaptively updated to achieve road handling and ride comfort. In
ABS design, a microcontroller typically is incorporated to read the
wheel speed from sensors, calculate the skid, and control
pressure in the brake cylinders. In addition, traction control and
diagnostics software will demand more processing capability on
the traditional controller.
20 Using the TMS320C24X DSP Controller for Optimal Digital Control
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Summary
This application report presents a new controller architecture: the
DSP controller and its single chip solutions for the control
applications. The TI TMS320C240 DSP controller combines the
performance of DSP architecture with the optimized peripherals of
a microcontroller. With this DSP controller, an intelligent control
and sensorless approach become possible. In addition, the
system cost will be reduced and the reliability of the entire system
will be improved.
References
TMS320C24x DSP Controllers, CPU, System, and Instruction Set,
Reference Set, Vol 1, 1997.
TMS320C24x DSP Controllers, Peripheral Library and Specific Devices,
Reference Set, Vol 2, 1997.
Digital Control Applications with the TMS320 Family, Irfan Admed, 1991.
DSP Solution for Permanent magnet Synchronous Motor, application
report from Texas Instruments, 1996
DSP Solution for AC Induction Motor, application report from Texas
Instruments, 1996
Using the TMS320C24X DSP Controller for Optimal Digital Control 21
