License

Public Domain

Recommend Projects

RODYNE EV Motor Controller

1 year ago 553
  • Description
  • Documents
  • BOM
  • Attachments
  • Members
  • Comments

Description

The Gate Drivers should power IGBT Half Bridge Drivers with gate drive up to around +15V/-8V at 10A so should work with most 3 phase BLDC and AC motors up to around 150KW eg a Nissan Leaf Motor at 400V would be fine. It should also work beyond this power level with better IGBTs or higher voltages though you may have to beef up the MOSFET Driver and Gate Power Supplies in some cases. Likewise the system board can also be used to control a lower voltage 72V-144V Forklift Series Wound DC Motor with just a single channel (for forward only) or 4 channels in 2 x half bridge configuration for forward/reverse control with just software changes and the components on extra channels can be left unpopulated (there are more elegant solutions than having a mostly unpopulated PCB but it will work fine) Due to the higher currents required for similar power at lower voltages the gate drive current of the IGBT may be a limiting factor and you would be better re-designing using parallel MOSFETs, again plenty of info out there if you google had enough.

Not shown are the Power Components, the 3 x Half Bridge IGBTs, Free-Wheeling Diodes, Fuses, Contactors, DC-Link Capacitors etc that control the high currents and so are better connected externally, these parts are well documented and the project builder is expected to know how they connect and the risks and safety requirements of working with very high voltages and currents.

Sensor inputs are provided for thermistors and current sense. Control inputs are provided for a 5K accellerator, 3 Switches and CAN Bus, 3 Open collector outputs are provided to drive relays such as the Main Contactor, Pre-Charge and another. The circuit is powered from the 12V Auxilliary battery, it is fused at a nominal 5A but a bit of experimentation may be required on this depending upon other chosen components.

Requires daughter MCU and resolver board fitted to operate (See seperate Project), the daughter board is seperate from motherboard to allow different MCU and Resolvers to be made if required as not everyone is familiar with the dsPIC and PGS411 resolver I use in my project.

The system design is based upon the Texas Instruments and ON Semiconductor Datasheets and Design References (TIDA-00917, AND9088) with input from a million other forums, all the questions you have can be answered from these and a bit of googling. I have tried to keep the parts as available as possible so generic substitutes can be made when the part enevitably goes out of stock. Most are from LCSC so a BOM and PCB can be built for under $100 from this EasyEDA link.

Usual disclaimer. This is public domain and while every effort has been made to ensure the circuit is accurate, it is experimental and mistakes may occur in design or build so it is up to the system builder to ensure it works.

Boz. July 2019

Documents

RODYNE EV Motor Controller Motherboard Schematic

PCB

BOM

ID Name Designator Footprint Quantity BOM_Supplier BOM_Supplier Part
1 2N7002 Q4,Q7,Q5,Q6,Q12,Q13,Q11,Q14,Q18,Q19,Q1 WSOT-23 11 LCSC C65189
2 1N4148W D15,D16,D17,D18,D31,D27 SOD123 6 LCSC C2099
3 INTERFACE U1 5569-2X12 PCB MOUNT 1 Digi-Key WM1362-ND
4 Wsense CN3 22035045 1 LCSC C37815
5 Vsense CN4 22035045 1 LCSC C37815
6 HVsense CN5 22035045 1 LCSC C37815
7 10 R18,R19,R20,R44,R45,R43 2512 6 LCSC C47019
8 4.7K R61,R67,R69,R63,R65,R62,R72 0805 7 LCSC C26022
9 LM5030SD U4 SDC10A 1 Digi-Key LM5030SD/NOPBCT-ND
10 EL357N(B)(TA)-G U15 SOP-4_P2.54 1 LCSC C6649
11 78M05 U2 TO-252-2 1 LCSC C111265
12 MCU-A P9 HDR-TH_40PIN-V-ROW2-COL20-FEMALE-PITCH2.54 1 LCSC C50982
13 MCU-B P10 HDR-TH_40PIN-V-ROW2-COL20-FEMALE-PITCH2.54 1 LCSC C50982
14 1K R7,R22,R23,R24,R47,R48,R46 0805 7 LCSC C17513
15 26.1K R2 0805 1 LCSC C104160
16 FOD8316R2 U7,U8,U9,U12,U13,U11 SOIC-16_300MIL 6 LCSC C80622
17 120Ω R81 R0805 1 LCSC C25280
18 2.4 R28,R29,R30,R53,R54,R52 2512 6 LCSC C25481
19 MAIN-FUSE 5A F1 FUSE_1812 1 LCSC C381482
20 B1100B13F D8,D3,D26,D22,D21,D4,D5,D6,D7,D9,D10,D11,D19,D20,D23,D24,D25 SMB(DO-214AA)-F 17 LCSC C124202
21 B1100B13F D2 SMB(DO-214AA)-F 1 LCSC C124202
22 LP5907QMFX-3.3Q1 U14 SOT-23-5 1 LCSC C130005
23 2.7K R9,R26,R25,R21,R4,R68,R70,R64,R66,R71,R73,R74,R75 0805 13 LCSC C17530
24 FAULT LED1 LED-1206 1 LCSC C84270
25 WB- LED15 LED-1206 1 LCSC C84270
26 WT- LED17 LED-1206 1 LCSC C84270
27 VB- LED11 LED-1206 1 LCSC C84270
28 VT- LED13 LED-1206 1 LCSC C84270
29 UB- LED18 LED-1206 1 LCSC C84270
30 UT- LED20 LED-1206 1 LCSC C84270
31 HEF4046BT,653 U5 SOIC-16_150MIL 1 LCSC C90682
32 10KΩ R31,R32,R40 R0805 3 LCSC C140868
33 750342312 T1,T2,T3 WURTH 750342312 500KHZ SMP TRANSFORMER 3 Digi-Key 1297-1223-ND
34 1K R49,R3,R56,R57,R5 0805 5 LCSC C115302
35 AMS1117-3.3_C165482 U3 SOT-223 1 LCSC C165482
36 100pF C59,C60,C62,C100,C101,C99 0805 6 LCSC C152851
37 25.5K R51,R55,R59,R60,R58,R86 2512 6 LCSC C175356
38 CON-HV+ P2 VH3.96-2A 1 LCSC C16728
39 IGBT-UT P3 VH3.96-2A 1 LCSC C16728
40 IGBT-UB P4 VH3.96-2A 1 LCSC C16728
41 IGBT-VT P5 VH3.96-2A 1 LCSC C16728
42 IGBT-VB P6 VH3.96-2A 1 LCSC C16728
43 IGBT-WT P7 VH3.96-2A 1 LCSC C16728
44 IGBT-WB P8 VH3.96-2A 1 LCSC C16728
45 US1M D12,D13,D14,D29,D30,D28 SMA(DO-214AC) 6 LCSC C5441
46 THERMISTER-IGBT3 CN1 XH-2AW 1 LCSC C33132
47 THERMISTER-4-MOTOR CN2 XH-2AW 1 LCSC C33132
48 ACCELERATOR-5K CN6 XH-2AW 1 LCSC C33132
49 THERMISTER-IGBT1 CN7 XH-2AW 1 LCSC C33132
50 THERMISTER-IGBT2 CN8 XH-2AW 1 LCSC C33132
51 49.9K R8,R87 0805 2 LCSC C17719
52 - L1 SMD-13.45X12.6-1365 1 LCSC C242230
53 PWR-12V LED3 LED-1206 1 LCSC C99881
54 PWR-3V3 LED4 LED-1206 1 LCSC C99881
55 ACTIVITY LED5 LED-1206 1 LCSC C99881
56 READY LED6 LED-1206 1 LCSC C99881
57 PWR-5V LED2 LED-1206 1 LCSC C99881
58 HV Active LED7 LED-1206 1 LCSC C99881
59 PWR-24V LED8 LED-1206 1 LCSC C99881
60 WB+ LED14 LED-1206 1 LCSC C99881
61 WT+ LED16 LED-1206 1 LCSC C99881
62 VB+ LED10 LED-1206 1 LCSC C99881
63 VT+ LED12 LED-1206 1 LCSC C99881
64 UB+ LED9 LED-1206 1 LCSC C99881
65 UT+ LED19 LED-1206 1 LCSC C99881
66 RESOLVER P1 HDR-IDC-2.54-2X4P 1 LCSC C9135
67 BSC070N10NS3GATMA1 Q20,Q21 PG-TDSON-8 2 LCSC C148247
68 100nF C16,C18,C23,C21,C10,C15,C17,C25,C12,C50,C105,C106,C107,C108,C110,C111,C112,C35,C94,C96,C98,C102,C104,C114,C115,C116,C117,C118,C119,C120,C121,C14,C19,C22,C122,C123,C124,C125,C126 0805 39 LCSC C1711
69 XL6019E1 U6 TO-263-5 1 LCSC C73018
70 100K R1 0805 1 LCSC C319972
71 10K R13,R10,R17,R16,R14,R11,R15,R12,R38,R35,R39,R36,R37,R34,R33,R42,R27,R50,R76,R77,R78,R79,R80,R82,R83,R84,R85 0805 27 LCSC C17414
72 10uF C29,C26,C32,C40,C46,C53,C38,C7,C2,C44,C51,C57,C63,C3,C8,C70,C67,C73,C76,C82,C88,C79,C85,C91,C97,C103,C113,C109,C27,C28,C30,C31,C33,C34,C36,C37,C39,C41,C42,C43,C45,C47,C48,C49,C52,C54,C55,C56,C58,C61,C64,C65,C66,C68,C69,C71,C72,C74,C75,C77,C78,C80,C81,C83,C84,C86,C87,C89,C90,C92,C93,C95 1210 72 LCSC C13585
73 470pF C20 0805 1 LCSC C61096
74 SB10100L D1 TO-277 1 LCSC C113946
75 1000uF C4,C5,C11 CAP-13*20 3 LCSC C88743
76 150uF C6,C9 CAP-D8.0XF3.5 2 LCSC C270008
77 DMC4029SK4-13 Q8,Q9,Q10,Q16,Q17,Q15 TO-252-4 6 LCSC C260864
78 22nF C1 0805 1 LCSC C326967
79 0.22 R6 2010 1 LCSC C146381

Attachments

None

Members

Success
The owner does not allow comments in this project now

Comments (0)

goToTop
你现在访问的是EasyEDA海外版,使用建立访问速度更快的国内版 https://lceda.cn(需要重新注册)
如果需要转移工程请在个人中心 - 工程 - 工程高级设置 - 下载工程,下载后在https://lceda.cn/editor 打开保存即可。
有问题联系QQ 3001956291 不再提醒
svg-battery svg-battery-wifi svg-books svg-more svg-paste svg-pencil svg-plant svg-ruler svg-share svg-user svg-logo-cn svg-double-arrow
We use cookies to offer you a better experience. Detailed information on the use of cookies on this website is provided in our Privacy Policy. By using this site, you consent to the use of our cookies.