High power, high performance 400V 300A 100 + KW motor controller is fully compatible with VESC.
This project is translated from HACKADAY, about it more history and article, please refer to HackADAY.
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What is it?
It is a three-phase motor controller. It requires a DC voltage that generates three sine waves of 3 drive motors using PWM, and is similar to small ESCs of drones and bicycles. Different, this special setting can be safely working with 400V batteries, flowing 300 year year.
Our work is mainly focused on the control board, the control panel can drive the roads above 400V, 300A above, these are defined by PowerStage (IGBTS, DC LINK capacitance, etc.).
We have chosen the economy dual IGBT module because it is a popular package, they are in many voltages and current levels (from 600V to 1700V, from 100A to 800A), from many brands, in IGBT and SiC technology and ready-made gate The drive matches them.
Why?
Because we want to be part of the most daring, the most spectacular build, no other open platforms can drive 100 kWh-level engines. What you can get is just a high-marked proprietary controller, you can't adjust them according to your needs, but more importantly, you can't see the internal working principle to assess whether the quality of software and hardware has reached your standard.
The new wave of electric vehicles have been bundled with the proprietary motor driver. We provide our customers with a chance to integrate motor drivers into their systems, providing a unique vertical opportunity in their products. . This saves costs and improves the quality and integration of the vehicle.
Axiom has also shown our quality of work and make our team an ideal contractor. There is not much person in the world with skills and knowledge of high performance drive units.
Axiom has also become possible, thank you for steady growth of VESC's base platforms, we can bring them the next level, from a hobby tool to fully support EV technology.
How did it work?
As we said, long-distance short, it requires a battery voltage (high voltage EDC) and generating 3 sinusoidal propagation 120 ° drive motors using PWM. In fact, it uses spatial vector modulation (SVM), reducing the amount of switching, thereby reducing switching loss.
Although VESC supports driving motors in trapezoidal and live-oriented control mode, our board works only in FOC. It is just more suitable for the application.
FOC is about adjusting the actual field inside the sine wave and the motor, and controls the torque generating current and flux (IQ) of the machine to generate current and flux (ID). About this topic has a lot of good references, you can see the actual code rows that perform conversion here.
In addition to the control loop, you also need a user interface to configure motor parameters, which will be your debugging issues and tools for the machine. Pay tribute to Benjamin's VESC tools:
Now I have learned some motor control algorithms, and a high-power algorithm process will require some very special hardware:
The following is some of the design tricks we found when making the project:
Mechanically matches the ECONDUAL / 17MM IGBT module. More compact, fewer assembly steps, fewer wiring and curl, no adapter parts.
Independent high voltage DC and phase voltage monitoring is integrated on board, directly connected to the cleaner signal and faster assembly of IGBTS.
DC capacitor discharge resistor on the boat. Safety requirements, emissions in the case of uninterrupted.
Measuring the RF connector of the analog signal. This provides a similar simulated signal quality, which is ideal for development.
Independent IGBT troubleshooting. You can see which IGBT has a problem.
Individual faults LEDs are used for overvoltage, overcurrent, and overheating.
Individual IGBT temperature monitoring.
A lattice ICE40 FPGA uses an open source toolchain for Sinthesis and HDL development.
FPGA is constantly monitoring all fault inputs. If any fault is asserted, all PWM activity is turned off.
The FPGA monitors PWM generated by the single chip. If the transmit command is detected, turn off the PWM.
RJ45 port. These are not Ethernet, which provide a standard ready-made shield twisted pair.
Dual simulation accelerator input.
Double isolated CANBUS interface (the firmware of the second interface is not yet).
The parser support.
BIS absolute encoder support (development under firmware).
Sin / due to encoder support.
Provide an adjustable 15VDC for the gate driver and monitors the voltage.
DAC output with RF connector can peek inside the firmware.
Open circuit drain output for driving small load or relays (e.g., pumps).
More fuses, more TV, more electromagnetic interference filtration.
Our other product:
