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System for Motor Control in a Solar Powered Electric Race Car. Jay Oatts Duncan Thompson Pavel Rybakov Alex Jenkins Ed Kfir Monday December 13, 2010. Solar Jackets – Motor Controller Group. ECE 4007L01 – ws3. Project Overview.
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System for Motor Control in a Solar Powered Electric Race Car Jay Oatts Duncan Thompson PavelRybakov Alex Jenkins Ed Kfir Monday December 13, 2010 Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Project Overview • Design motor controlling system and driver vitals display for solar-powered race car to participate in 2011 World Solar Challenge in Australia • Modular and mostly generic design for efficient portability of some or all of the project to the final solar racer and integrating with other electronics systems present • Expected cost of replication for Solar Jackets is approximately $550 Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Technical Objectives (Proposed) • Design test bench and implement safety mechanisms • Test functionality of motor controller and motor (donated items) • Operate motor controller via single-board computer program and discrete controls • Output vital data from motor controller to driver via LCD screen Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Actual Design • Test rig confirmed operation (or failure) of donated parts (motors and controllers) • Safety mechanisms in place to reduce risk • Operation of motor in discrete (human interface) and serial (computer interface) confirmed • Program written to continuously monitor controller for status and vital information to be displayed onto LCD screen Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Modular Design Lots of interconnections! Break things down As much as possible Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Modular Design • Power Source Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Modular Design • Power Source • Motor Controller Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Modular Design • Power Source • Motor Controller • Motor Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Modular Design • Power Source • Motor Controller • Motor • Discrete Controls Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Modular Design • Power Source • Motor Controller • Motor • Discrete Controls • SBC Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Modular Design • Power Source • Motor Controller • Motor • Discrete Controls • SBC • Driver Display Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Actual Design Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Power Source - Batteries • 8 x 12V series connection • 96V effective • Wiring – AWG-4 Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Power Source - Fuse • 250V / 150A rated fuse and holder Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Power Source – Main Power Cutoff • 48V/96V blowout • 1000A • Keyed access Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Power Source – Power Relay • Contactor • 900V / 500A (cont.) / 2000A (cutoff) • Power Resistor • 100Ω/200W Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Motor Controller - Connections • Battery Terminals Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Motor Controller - Connections • Battery Terminals • Motor 3-Phase Power Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Motor Controller - Connections • Battery Terminals • Motor 3-Phase Power • Motor Sense (15 pin) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Motor Controller - Connections • Battery Terminals • Motor 3-Phase Power • Motor Sense (15 pin) • Discrete/Serial Controls (25 pin) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Motor Controller - Connections • Battery Terminals • Motor 3-Phase Power • Motor Sense (15 pin) • Discrete/Serial Controls (25 pin) • Fan Power Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Motor Controller - Connections • Battery Terminals • Motor 3-Phase Power • Motor Sense (15 pin) • Discrete/Serial Controls (25 pin) • Fan Power • Fans (2 x 24V) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Brushless Electric Motor • 3 phase cables connect to attract rotating permanent magnet in sequence • Controller sends power to phases relative to desired speed/torque (commutator) • Motor sense cable sends information back to controller (Hall effect sensors, temp sensor, connection sense) • Mount for support/stability Above: NGM electric motor attached to plate mount with wiring harness for phase cables and motor sense cable. Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Motor Controller - Communication • Split from 25 pin controls cable • Serial-USB for computer • Hyperterminal program Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Discrete Controls - Switches • Enable • Master controller enable (must be on to operate) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Discrete Controls - Switches • Enable • Master controller enable (must be on to operate) • Throttle Enable • Phase current enable (drops to zero when disabled, but regen still operational) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Discrete Controls - Switches • Enable • Master controller enable (must be on to operate) • Throttle Enable • Phase current enable (drops to zero when disabled, but regen still operational) • Direction Switch • Forward or Reverse Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Discrete Controls – Output Signals • Brake (Regen) Light • Activates anytime the controller is regenerating power back to batteries (Phase current negative) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Discrete Controls – Output Signals • Brake (Regen) Light • Activates anytime the controller is regenerating power back to batteries (Phase current negative) • Reverse Light • Activates when reverse switch set Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Discrete Controls – Output Signals • Brake (Regen) Light • Activates anytime the controller is regenerating power back to batteries (Phase current negative) • Reverse Light • Activates when reverse switch set • Speed Pulse • State change every two consecutive commutations • Unused in our design, but could be useful to analyze on an oscilloscope Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Discrete Controls – Pedals • Throttle • Analog input (potentiometer for now) to scale throttle from 0-5V Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Discrete Controls – Pedals • Throttle • Analog input (potentiometer for now) to scale throttle from 0-5V • Regenerative Braking • Same as throttle, but scales amount of regeneration to batteries from motor Note: The potentiometer design used in our design can be scaled for use with pedals. The controls require a 3 lead (vdd, gnd,wiper) configuration that is common to electric potentiometer foot pedals. Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Discrete Controls – Pedals • Throttle • Analog input (potentiometer for now) to scale throttle from 0-5V • Regenerative Braking • Same as throttle, but scales amount of regeneration to batteries from motor • Air Gap • NGM thought they could do this, but apparently backed out after the control cable was designed Note: The potentiometer design used in our design can be scaled for use with pedals. The controls require a 3 lead (vdd, gnd,wiper) configuration that is common to electric potentiometer foot pedals. Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Single Board Computer (SBC) - External • Serial connection to laptop on COM1 for loading and viewing programs Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Single Board Computer (SBC) - External • Serial connection to laptop on COM1 for loading and viewing programs • 10/100 Ethernet port could also be used Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Single Board Computer (SBC) - External • Serial connection to laptop on COM1 for loading and viewing programs • 10/100 Ethernet port could also be used • SBC external power source, 5V Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Single Board Computer (SBC) - External • Serial connection to laptop on COM1 for loading and viewing programs • 10/100 Ethernet port could also be used • SBC external power source, 5V Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Single Board Computer (SBC) - Internal • Serial connection to motor controller via discrete controls box on COM2 expansion Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Single Board Computer (SBC) - Internal • Serial connection to motor controller via discrete controls box on COM2 expansion • Connection to LCD screen and cruise control switches with Digital Input/Output (DIO) pins Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Communication and Programming • USB to Serial • Connects to COM1 on SBC • C code compiled in Cygwin • Unix environment for Windows • Additional compiler installed specifically for ARM processor on SBC • Transferred to SBC with Hyperterminal • Run binary executable on SBC Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Console Program • Displays information received from motor controller every second • Can turn off this mode for smoother LCD functionality • Roundabout debugging system using print statements in various sections of code for testing Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
LCD & Cruise Control • Potential display choice Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Driver LCD Display • Potential display choice • Advantages • Cheap! • Our example is already in easily modifiable code • Many colors and backlighting options • Low power (about 150uA) • Disadvantages • Small(128x64px) • Additional graphics will have to be hard coded Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Driver LCD Display • Display parameters • Battery supply voltage • Range 96V – 100% to 50V – 0% Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Driver LCD Display • Display parameters • Battery supply voltage • Range 96V – 100% to 50V – 0% • Throttle/Regen Current • Range from 0A (middle) to +/- 25A • Above = throttling, below = regenerating • Values will need to be higher once load tested Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Driver LCD Display • Display parameters • Direction (Forward or reverse) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Driver LCD Display • Display parameters • Direction (Forward or reverse) • Cruise Control (On or Off) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Driver LCD Display • Display parameters • Direction (Forward or reverse) • Cruise Control (On or Off) • Speed (Calculated from RPM and wheel size) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Driver LCD Display • Display parameters • Direction (Forward or reverse) • Cruise Control (On or Off) • Speed (Calculated from RPM and wheel size) • Temperatures (Motor/ Motor Controller) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3
Driver LCD Display • Display parameters • Direction (Forward or reverse) • Cruise Control (On or Off) • Speed (Calculated from RPM and wheel size) • Temperatures (Motor/ Motor Controller) • Fault Codes (Hexadecimal, match to motor controller manual) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3