Brushless motor controller Allegro a4964

Other Hardware Motors, Mechanics, Power and CNC
1

Hello everyone,

I am working on a project to control a brushless pump using the Allegro A4964 driver. The motor I’m using has 2 pole pairs, and I’ve been following the implementation from this repository: Kiel_50 GitHub Repository.

Despite my efforts, I haven’t been able to achieve proper operation. Here’s the current situation:

  • Behavior:
    • Sometimes the motor starts spinning, but it’s not correct and seems erratic.
    • Other times, the motor only vibrates without spinning.
  • Setup Details:
    • Brushless pump with 2 pole pairs.
    • Allegro A4964 driver IC.
    • Configuration and code based on the provided GitHub repository.

I’ve double-checked the connections and wiring, as well as the configurations in the code. However, the motor behavior suggests there might be an issue with the driver setup or the commutation algorithm.

Has anyone here worked with the A4964 or encountered similar issues? Any advice on how to debug or resolve this would be greatly appreciated.

Thank you in advance for your insights and suggestions. Looking forward to hearing from the community!

2

Please post a link to the datasheet.

Please post a link to the datasheet.

Please post schematics.

Please post the code, using code tags

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1 Like
3

Hello,

Sorry you are correct

i dont have the datasheet of the fuel pump i know only that is from Audi R8 2018
and it has 2 poles pair as I count.

Allegro A4964 Datasheet

The code is from this repository GitHub - WiderstandD/Kiel_50: BLDC sine wave controller shield for Arduino UNO

/*
 * Author: Mark Gajevskis
 * Date: 9 March 2019
 * Board: Arduino UNO
 * Chip: A4964
 * Communication protocol: 4-wire HW SPI
 * Logic voltage: 5V
 * Logic voltage shiftig: NO
 * USART baudrate: 115200
 * 
 * 
 * 
 * This code write the "Register Select" in 
 * order to set the register 31 in Read Only 
 * mode. The data is send to the host pc via UART.
 * 
 * 
 */

#include "Arduino.h"
#include "main.h"
#include "SPI.h"
#include "motor_settings.h"


uint16_t countSetBits(unsigned int n)
{
  unsigned int count = 0;
  while (n)
  {
    count += n & 1;
    n >>= 1;
  }
  return count;
}

void dialup(uint16_t addr, uint16_t val) {

  foo = (addr | SPI_WRITE | val);
  count = countSetBits(foo);

  if ((count % 2) == 0) {
    foo2 = (foo | PARITY);
    Serial.print("if passed, counter: ");
    Serial.println(count);
    Serial.print("parity result: ");
    Serial.println(foo2, BIN);

    SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3));
    digitalWrite(PIN_CS, LOW);
    SPI.transfer16(foo2);
    digitalWrite(PIN_CS, HIGH);
  }
  else {
    Serial.print("else...no parity: ");
    Serial.println(foo, BIN);

    SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3));
    digitalWrite(PIN_CS, LOW);
    SPI.transfer16(foo);
    digitalWrite(PIN_CS, HIGH);
  }
  Serial.println("dialup_end");
}

void temperature() {

  SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3)); // Start SPI dialog with settings for A4964
  digitalWrite(PIN_CS, LOW);
  SPI.transfer16(REG_BRS_TEMP);  // Write the RBS in temperature rading mode
  digitalWrite(PIN_CS, HIGH);

  SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3)); // Start SPI dialog with settings for A4964
  digitalWrite(PIN_CS, LOW);
  rdng_temp = SPI.transfer16(REG_RD_ONLY);  // Read the register 31
  digitalWrite(PIN_CS, HIGH);

  Serial.print("Temperature: ");
  Serial.println((367.7 - ((rdng_temp & 0b11111111110) >> 1) * 0.451), 2); // Refer to A4964 manual page 77
}

void showspeed() {

  SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3)); // Start SPI dialog with settings for A4964
  digitalWrite(PIN_CS, LOW);
  SPI.transfer16(REG_RBS_SPEED);  // Write the RBS in temperature rading mode
  digitalWrite(PIN_CS, HIGH);

  SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3)); // Start SPI dialog with settings for A4964
  digitalWrite(PIN_CS, LOW);
  rdng_speed = SPI.transfer16(REG_RD_ONLY);  // Read the register 31
  digitalWrite(PIN_CS, HIGH);

  Serial.print("Speed (rpm): ");
  Serial.println((((((rdng_speed & 0b11111111110) >> 1) * 1.6) * 60) / 7), 4); // Refer to A4964 manual page 77

  SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3)); // Start SPI dialog with settings for A4964
  digitalWrite(PIN_CS, LOW);
  rdng_speed = SPI.transfer16(REG_RD_ONLY);  // Read the register 31
  digitalWrite(PIN_CS, HIGH);

  Serial.print("Speed (Hz): ");
  Serial.println((((rdng_speed & 0b11111111110) >> 1) * 1.6), 4); // Refer to A4964 manual page 77
}

void duty_cycle() {

  SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3)); // Start SPI dialog with settings for A4964
  digitalWrite(PIN_CS, LOW);
  SPI.transfer16(REG_RBS_DUTY_CYCLE);  // Write the RBS in voltage rading mode
  digitalWrite(PIN_CS, HIGH);

  SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3)); // Start SPI dialog with settings for A4964
  digitalWrite(PIN_CS, LOW);
  rdng_duty_cycle = SPI.transfer16(REG_RD_ONLY);  // Read the register 31
  digitalWrite(PIN_CS, HIGH);
  Serial.print("Peak Duty Cycle: ");
  Serial.println((((rdng_duty_cycle & 0b11111111110) >> 1) / 1023) * 100, 3);
}

void applied_phase_advance() {

  SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3)); // Start SPI dialog with settings for A4964
  digitalWrite(PIN_CS, LOW);
  SPI.transfer16(REG_RBS_PHASE_ADV);  // Write the RBS in voltage rading mode
  digitalWrite(PIN_CS, HIGH);

  SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3)); // Start SPI dialog with settings for A4964
  digitalWrite(PIN_CS, LOW);
  rdng_phase_adv = SPI.transfer16(REG_RD_ONLY);  // Read the register 31
  digitalWrite(PIN_CS, HIGH);
  Serial.print("Applied Phase Advance: ");
  Serial.println(((rdng_phase_adv & 0b11111111110) >> 1) * 0.7, 3);
}

void voltage() {

  SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3)); // Start SPI dialog with settings for A4964
  digitalWrite(PIN_CS, LOW);
  SPI.transfer16(REG_RBS_VOLT);  // Write the RBS in voltage rading mode
  digitalWrite(PIN_CS, HIGH);

  SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3)); // Start SPI dialog with settings for A4964
  digitalWrite(PIN_CS, LOW);
  rdng_volt = SPI.transfer16(REG_RD_ONLY);  // Read the register 31
  digitalWrite(PIN_CS, HIGH);
  Serial.print("Voltage: ");
  Serial.println(((rdng_volt & 0b11111111110) >> 1) * 0.0528, 3);
}

void current() {

  SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3)); // Start SPI dialog with settings for A4964
  digitalWrite(PIN_CS, LOW);
  SPI.transfer16(REG_RBS_CURRENT);  // Write the RBS in current rading mode
  digitalWrite(PIN_CS, HIGH);

  SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3)); // Start SPI dialog with settings for A4964
  digitalWrite(PIN_CS, LOW);
  rdng_current = SPI.transfer16(REG_RD_ONLY);  // Read the register 31
  digitalWrite(PIN_CS, HIGH);
  Serial.print("Current: ");
  Serial.println(((((rdng_current & 0b11111111110) >> 1) / 50) * 1.76), 3);
}

void writeregisters() {

  dialup(ADDR_PWM_CONF_0, MOD_3 | PMD_CENTER | PW_PWM_FREQ(0b100110));
  //dialup(ADDR_PWM_CONF_1, DS_DITHER_DISABLE),
  dialup(ADDR_PWM_CONF_1, DP_PERIOD_1_2 | DD_TIME_2 | DS_STEP_COUNT_15);
  dialup(ADDR_BRGE_CONF, SA_AMP_GAIN_2_5 | DT_MOSFET_500);
  dialup(ADDR_GATE_DRV_CONF_0, IR1_ON_40 | IR2_ON_10);
  dialup(ADDR_GATE_DRV_CONF_1, IF1_OFF_60 | IF2_OFF_15);
  dialup(ADDR_GATE_DRV_CONF_2, TRS_ON_TIME_300 | TFS_OFF_TIME_600);
  dialup(ADDR_I_LIM_CONF, OBT_BLANK_TIME_3_6 | VIL_SCALE_16_16);
  dialup(ADDR_VDS_0, MIT_TRESHOLD_200 | VT_V_TRESHOLD_1_2);
  dialup(ADDR_VDS_1, VDQ_DEBOUNCE | VQT_QUAL_TIME_1_2);
  dialup(ADDR_WATCH_DOG_0, WM_MIN_TIME_21);
  dialup(ADDR_WATCH_DOG_1, WC_DISABLE);     // Register Nr. 10
  dialup(ADDR_COMMT_0, CP_SS_PROP_GAIN_2 | CP_SS_INTEG_GAIN_2);
  dialup(ADDR_COMMT_1, CPT_TC_PROP_GAIN_2 | CIT_TC_INTEG_GAIN_2);
  dialup(ADDR_BEMF_CONF_0, BW_DETECT_WINDOW(0b11111));
  dialup(ADDR_BEMF_CONF_1, BS_SMPL_CYCLE_6 | BF_WM_FILTER_TIME_200);
  dialup(ADDR_STR_CONF_0, HT_ALIGMENT_400 | HD_PWM_ALIG_3_125);   // Register Nr. 15
  dialup(ADDR_STR_CONF_1, STM_COASM_OFF | RSC_OFF | KM_RATIO_0_30 | HR_DUTY_CYCLE_0);
  dialup(ADDR_STR_CONF_2, WIN_MODE_OFF);
  dialup(ADDR_STR_CONF_3, SF2_FINAL_FREQ_10 | SF1_INITIAL_FREQ_0_5);
  dialup(ADDR_STR_CONF_4, SD2_FINAL_CYC_18_75 | SD1_INITIAL_CYC_6_25);
  dialup(ADDR_STR_CONF_5, STS_STEP_TIME_160 | SFS_FINAL_RAMP_FREQ(0b0011));  // Register Nr. 20
  dialup(ADDR_SPEED_LOOP_0, SGL_ACCELER_LIM(0b00111) | SG_GAIN(0b1000));
  dialup(ADDR_SPEED_LOOP_1, DV_CYCLE_COMP_OFF | DF_DECEL_FACTOR_1 | SR_SPEED_CTRL_RES_0_1);
  dialup(ADDR_SPEED_LOOP_2, SL_LOW_THRESHOLD(0b0001) | SH_HIGH_THRESHOLD(0b1100));
  dialup(ADDR_SYS, ESF_NO_STOP_ON_FAIL | VLR_LOGIC_V_5 | VRG_GATE_V_8 | OPM_STAND_ALONE | LWK_PWM_WAKE_MDOE | IPI_ACT_LOW | DIL_I_LIM_OFF | CM_CLOSED_LOOP_SPEED_2); // REG Nr. 25
  dialup(ADDR_PHA_ADV, PAM_PHASE_ADV_AUTO | KIP_AUTO_PHASE_CTRL_4);
  dialup(ADDR_MOT_FUN, LEN_LIN_STANDBY | GTS_NO_CHANGE_0 | OVM_OVERMOD_OFF | DRM_MODE_SINE | BRK_ON | DIR_REVERSE | RUN_ON);
}

void speedreference(){

  const int analogPin = A0;
  uint16_t A0_val = 0;
  uint16_t A0_conv = 0;
  uint16_t A0_ready = 0;
  // The "A0_val" is 10bit meaning 0 to 1023 dec. long. Need to be converted to 9bit meaning 0 to 511 dec. long.
  A0_val = analogRead(analogPin);
  A0_conv = map(A0_val, 0, 1023, 0, 511);
  // To do: Shift converted value to 1 bit left
  A0_ready = (A0_conv << 1);
  // To do: Output the "Fref" to Serial interface in Hz
  Serial.print("BINary data A0_ready: ");
  Serial.println(A0_ready, BIN);

  Serial.print("Speed ref in Hz: ");
  Serial.println(SR_SPEED_CTRL_RES_1_6 * A0_ready, DEC);
  // To do: Sent SPI data to "ADDR_WRT_ONLY"
  foo = (ADDR_WRT_ONLY | A0_ready);
  count = countSetBits(foo);

  if ((count % 2) == 0) {
    foo2 = (foo | PARITY);

    SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3));
    digitalWrite(PIN_CS, LOW);
    SPI.transfer16(foo2);
    digitalWrite(PIN_CS, HIGH);
  }
  else {

    SPI.beginTransaction(SPISettings(SPI_SPEED, MSBFIRST, SPI_MODE3));
    digitalWrite(PIN_CS, LOW);
    SPI.transfer16(foo);
    digitalWrite(PIN_CS, HIGH);
  }
}


void setup() {

  SPI.begin();
  pinMode(PIN_CS, OUTPUT);

  Serial.begin(115200);
  delay(100);

  writeregisters();
}

void loop() {

  temperature();
  voltage();
  current();
  showspeed();
  duty_cycle();
  applied_phase_advance();
  speedreference();
  Serial.println();
  delay(200);
}

The shematic is the following

image
image1920×1359 287 KB

4

Great. You have all connections there including the motor driver parts. They are for a 3 phase BLDC motor, I think.
The motor description doesn't make it clear. Is there any label on the motor?

5

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