Dual-core processor F28M35 in line protection applications

In the field of power protection, the evolution has progressed from early 8-bit microcontrollers to 16-bit and 32-bit processors, which have largely met the requirements for integrated microcomputer protection devices. However, as power industry technology continues to advance, the complexity of protection algorithms has increased, and Ethernet communication has become widely adopted. This has exposed limitations in the capacity of the mainstream TMS320F2812 processor in system management and network communication. To meet the new demands of users, the company has developed a next-generation integrated microcomputer protection device based on TI’s dual-core processor, F28M35. First, let's explore the features of the F28M35. This industrial-grade dual-core chip integrates an ARM Cortex-M3 core and a DSP C28 core. It includes dedicated 4KB RAM and communication flag registers that form the internal processor communication module – IPC. The F28M35 offers up to 128KB of on-chip RAM, with 64KB available for allocation between the two cores. The program space is 512KB + 512KB. The M3 core can access up to 512MB of external data space and comes equipped with USB, Ethernet, UART, I2C, and SPI interfaces, meeting most industrial control needs. Its system clock can reach up to 100MHz. The C28 core stands out with the addition of a single-precision hardware floating-point calculation unit, making programming more convenient without sacrificing speed and lowering the programming threshold. It can operate at up to 150MHz. Next, the hardware design of the protection device. The system comprises voltage and current transformers, a 16-channel ADC, relay outputs, an LCD interface, key input, digital inputs, a 485 communication interface, an Ethernet interface, the dual-core F28M35 processor, and a power supply. A schematic diagram is shown below: Now, looking at the software task division and structure. The C28 core handles fewer tasks, and a main program loop with a 200us interrupt is sufficient to perform the following: - Operate two MAX125 14-bit, 8-channel ADC chips and acquire 16 channels of AD values every 200us. - Perform software frequency measurement on each channel to determine the actual AC signal frequency and period. - Virtualize 96 AD samples per cycle per channel using the calculated period and AD sampling value. - Conduct a 96-point FFT operation to obtain amplitude and phase for each channel. - Perform higher harmonic FFT to extract amplitudes of harmonics from 2nd to 11th. - Execute all logic decisions to determine if a protection action is needed. - Communicate internally with the M3 core for real-time data exchange. On the other hand, the M3 core manages more tasks by using the UCOSII real-time operating system to handle: - Displaying LCD menu parameters and corresponding button operations. - Managing Ethernet and RS485 communications, including 103 protocol processing. - Configuring and saving system parameters, including through the communication port. - Recording and storing action and alarm logs. - Saving all analog input channels. - Exchanging data with the C28 core in real time. Finally, the implementation results show significant improvements compared to similar products. The measurement accuracy of the 5A transformer reached 0.1% at 1A input, and the quick-break action time was reduced to 24ms. In addition, various network communication functions were added, while the processor cost remained almost unchanged. After entering small-scale production, the product received positive feedback from users, who confirmed its reliability and accuracy after long-term on-site testing. It is clear that the F28M35 dual-core processor offers excellent cost-performance and holds great potential for use in industrial applications requiring high reliability, real-time performance, and complex functionality. It is expected to be widely adopted in the future.

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