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ABOUT ME …
MOTOR CONTROLLERS
• What do they do?
• Terminology
BASIC CLASSIFICATION
• Input: DC, AC (1 phase, 3 phase)
• Outut: DC, AC (1 phase, 3 phase)
COMMON TRACTION MOTORS
• Low HP: PM brushed DC, brushless DC
• High HP: series wound DC, SepEx,
3ph induction AC
RATINGS
• Voltage
• Battery pack voltage
• Charging voltage
• Current
• Peak rating (what time?)
• Continuous (1 hour) rating
• How much (what kind) of heat dissipation?
• Thermal protection?
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NON-REVERSING
NON-REGENING CIRCUIT (1Q)
DC
VOLTAGE
SOURCE
VOLTAGE
DC
MOTOR
CURRENT
DC
VOLTAGE
SOURCE
PMDC
MOTOR
AVERAGE
VOLTAGE
NON-REVERSING
REGENING CIRCUIT (2Q)
DC
VOLTAGE
SOURCE
DC
MOTOR
REVERSING
REGENING CIRCUIT (4Q)
DC
VOLTAGE
SOURCE
DC
MOTOR
THREE PHASE
INVERTER BRIDGE
DC
VOLTAGE
SOURCE
BLDC/AC
MOTOR
BUILDING BLOCKS
B+
M-
DC VOLTAGE
SOURCE
MOTOR
BMOSFET/IGBT DRIVER
CIRCUITRY
POWER
SUPPLY
CIRCUIT
MOTOR
CURRENT
SENSING
BATTERY
VOLTAGE
SENSING
MOTOR
VOLTAGE
SENSING
MICROCONTROLLER
COMMAND SIGNALS,
INTERLOCKS, AND
ADJUSTMENTS
DIAGNOSTIC
(LED, LCD)
COMMUNICATION
PORTS
SPEED
FEEDBACK
CONDITIONING
DESIGN CONSIDERATIONS
• Power component choice (MOSFET, IGBT)
• Power module vs. paralleling
• Structural arrangement
• Enclosing (sealed or not)
• Power supply circuit (linear, switch-mode)
• Gate drivers (discrete, Integrated circuit)
• Current sensing (shunt, hall effect)
DESIGN PROCESS
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Circuit schematic
PC Boards layout
Microcontroller code writing
Mechanical design/drawings
Prototypes built
Performance testing
Heat testing
In-application testing
DC vs. AC ….
DEMOS…