1 / 67

System for Motor Control in a Solar Powered Electric Race Car

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.

lilli
Download Presentation

System for Motor Control in a Solar Powered Electric Race Car

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. 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

  2. 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

  3. 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

  4. 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

  5. Modular Design Lots of interconnections! Break things down As much as possible Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  6. Modular Design • Power Source Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  7. Modular Design • Power Source • Motor Controller Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  8. Modular Design • Power Source • Motor Controller • Motor Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  9. Modular Design • Power Source • Motor Controller • Motor • Discrete Controls Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  10. Modular Design • Power Source • Motor Controller • Motor • Discrete Controls • SBC Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  11. Modular Design • Power Source • Motor Controller • Motor • Discrete Controls • SBC • Driver Display Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  12. Actual Design Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  13. Power Source - Batteries • 8 x 12V series connection • 96V effective • Wiring – AWG-4 Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  14. Power Source - Fuse • 250V / 150A rated fuse and holder Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  15. Power Source – Main Power Cutoff • 48V/96V blowout • 1000A • Keyed access Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  16. Power Source – Power Relay • Contactor • 900V / 500A (cont.) / 2000A (cutoff) • Power Resistor • 100Ω/200W Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  17. Motor Controller - Connections • Battery Terminals Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  18. Motor Controller - Connections • Battery Terminals • Motor 3-Phase Power Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  19. Motor Controller - Connections • Battery Terminals • Motor 3-Phase Power • Motor Sense (15 pin) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  20. 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

  21. 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

  22. 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

  23. 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

  24. Motor Controller - Communication • Split from 25 pin controls cable • Serial-USB for computer • Hyperterminal program Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  25. Discrete Controls - Switches • Enable • Master controller enable (must be on to operate) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  26. 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

  27. 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

  28. 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

  29. 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

  30. 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

  31. Discrete Controls – Pedals • Throttle • Analog input (potentiometer for now) to scale throttle from 0-5V Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  32. 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

  33. 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

  34. Single Board Computer (SBC) - External • Serial connection to laptop on COM1 for loading and viewing programs Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  35. 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

  36. 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

  37. 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

  38. 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

  39. 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

  40. 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

  41. 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

  42. LCD & Cruise Control • Potential display choice Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  43. 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

  44. Driver LCD Display • Display parameters • Battery supply voltage • Range 96V – 100% to 50V – 0% Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  45. 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

  46. Driver LCD Display • Display parameters • Direction (Forward or reverse) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  47. Driver LCD Display • Display parameters • Direction (Forward or reverse) • Cruise Control (On or Off) Solar Jackets – Motor Controller Group ECE 4007L01 – ws3

  48. 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

  49. 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

  50. 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

More Related