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RODYNE EV Motor Controller

4 months ago 151
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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 Part BOM_Supplier
1 750342312 T1,T2,T3 WURTH 750342312 500KHZ SMP TRANSFORMER 3 1297-1223-ND Digi-Key
2 LM5030SD U4 SDC10A 1 LM5030SD/NOPBCT-ND Digi-Key
3 B1100B13F D8,D3,D26,D22,D21,D4,D5,D6,D7,D9,D10,D11,D19,D20,D23,D24,D25,D2 SMB(DO-214AA)-F 18 C124202 LCSC
4 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 C13585 LCSC
5 0.22 R6 2010 1 C146381 LCSC
6 26.1K R2 0805 1 C104160 LCSC
7 100K R1 0805 1 C319972 LCSC
8 22nF C1 0805 1 C326967 LCSC
9 FOD8316R2 U7,U8,U9,U12,U13,U11 SOIC-16_300MIL 6 C80622 LCSC
10 100pF C59,C60,C62,C100,C101,C99 0805 6 C152851 LCSC
11 2N7002 Q4,Q7,Q5,Q6,Q12,Q13,Q11,Q14,Q18,Q19,Q1 WSOT-23 11 C65189 LCSC
12 1K R7,R22,R23,R24,R47,R48,R46,R49,R3,R56,R57,R5 0805 12 C115302 LCSC
13 78M05 U2 TO-252-2 1 C111265 LCSC
14 DMC4029SK4-13 Q8,Q9,Q10,Q16,Q17,Q15 TO-252-4 6 C260864 LCSC
15 2.4 R28,R29,R30,R53,R54,R52 2512 6 C25481 LCSC
16 10 R18,R19,R20,R44,R45,R43 2512 6 C47019 LCSC
17 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 C17414 LCSC
18 US1M D12,D13,D14,D29,D30,D28 SMA(DO-214AC) 6 C5441 LCSC
19 AMS1117-3.3_C165482 U3 SOT-223 1 C165482 LCSC
20 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 C1711 LCSC
21 1N4148W D15,D16,D17,D18,D31,D27 SOD123 6 C2099 LCSC
22 10KΩ R31,R32,R40 R0805 3 C140868 LCSC
23 INTERFACE U1 5569-2X12 PCB MOUNT 1 WM1362-ND Digi-Key
24 XL6019E1 U6 TO-263-5 1 C73018 LCSC
25 - L1 SMD-13.45X12.6-1365 1 C242230 LCSC
26 150uF C6,C9 CAP-D8.0XF3.5 2 C270008 LCSC
27 MAIN-FUSE 5A F1 FUSE_1812 1 C381482 LCSC
28 SB10100L D1 TO-277 1 C113946 LCSC
29 49.9K R8,R87 0805 2 C17719 LCSC
30 2.7K R9,R26,R25,R21,R4,R68,R70,R64,R66,R71,R73,R74,R75 0805 13 C17530 LCSC
31 470pF C20 0805 1 C61096 LCSC
32 LP5907QMFX-3.3Q1 U14 SOT-23-5 1 C130005 LCSC
33 THERMISTER-IGBT3 CN1 XH-2AW 1 C33132 LCSC
34 THERMISTER-4-MOTOR CN2 XH-2AW 1 C33132 LCSC
35 Wsense CN3 22035045 1 C37815 LCSC
36 Vsense CN4 22035045 1 C37815 LCSC
37 ACCELERATOR-5K CN6 XH-2AW 1 C33132 LCSC
38 PWR-12V LED3 LED-1206 1 C99881 LCSC
39 PWR-3V3 LED4 LED-1206 1 C99881 LCSC
40 ACTIVITY LED5 LED-1206 1 C99881 LCSC
41 READY LED6 LED-1206 1 C99881 LCSC
42 FAULT LED1 LED-1206 1 C84270 LCSC
43 PWR-5V LED2 LED-1206 1 C99881 LCSC
44 HV Active LED7 LED-1206 1 C99881 LCSC
45 25.5K R51,R55,R59,R60,R58,R86 2512 6 C175356 LCSC
46 CON-HV+ P2 VH3.96-2A 1 C16728 LCSC
47 IGBT-UT P3 VH3.96-2A 1 C16728 LCSC
48 IGBT-UB P4 VH3.96-2A 1 C16728 LCSC
49 PWR-24V LED8 LED-1206 1 C99881 LCSC
50 4.7K R61,R67,R69,R63,R65,R62,R72 0805 7 C26022 LCSC
51 IGBT-VT P5 VH3.96-2A 1 C16728 LCSC
52 IGBT-VB P6 VH3.96-2A 1 C16728 LCSC
53 IGBT-WT P7 VH3.96-2A 1 C16728 LCSC
54 IGBT-WB P8 VH3.96-2A 1 C16728 LCSC
55 WB+ LED14 LED-1206 1 C99881 LCSC
56 WB- LED15 LED-1206 1 C84270 LCSC
57 WT+ LED16 LED-1206 1 C99881 LCSC
58 WT- LED17 LED-1206 1 C84270 LCSC
59 VB+ LED10 LED-1206 1 C99881 LCSC
60 VB- LED11 LED-1206 1 C84270 LCSC
61 VT+ LED12 LED-1206 1 C99881 LCSC
62 VT- LED13 LED-1206 1 C84270 LCSC
63 UB+ LED9 LED-1206 1 C99881 LCSC
64 UB- LED18 LED-1206 1 C84270 LCSC
65 UT+ LED19 LED-1206 1 C99881 LCSC
66 UT- LED20 LED-1206 1 C84270 LCSC
67 THERMISTER-IGBT1 CN7 XH-2AW 1 C33132 LCSC
68 THERMISTER-IGBT2 CN8 XH-2AW 1 C33132 LCSC
69 HVsense CN5 22035045 1 C37815 LCSC
70 RESOLVER P1 HDR-IDC-2.54-2X4P 1 C9135 LCSC
71 MCU-A P9 HDR-TH_40PIN-V-ROW2-COL20-FEMALE-PITCH2.54 1 C50982 LCSC
72 MCU-B P10 HDR-TH_40PIN-V-ROW2-COL20-FEMALE-PITCH2.54 1 C50982 LCSC
73 1000uF C4,C5,C11 CAP-13*20 3 C88743 LCSC
74 HEF4046BT,653 U5 SOIC-16_150MIL 1 C90682 LCSC
75 EL357N(B)(TA)-G U15 SOP-4_P2.54 1 C6649 LCSC
76 120Ω R81 R0805 1 C25280 LCSC
77 BSC070N10NS3GATMA1 Q20,Q21 PG-TDSON-8 2 C148247 LCSC

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