10kW Compact BLDC Motor Reference Design

The 10kW BLDC motor reference design options in depth protections and helps high-performance motor management for e-scooters, e-bikes, drones, and UAVs.

The demand for micro-mobility gadgets like e-scooters and e-bikes is rising as a result of want for fuel-efficient transportation and considerations about carbon emissions. Elevated adoption and improvement of electrical powertrains for these autos drive this development. The worldwide marketplace for electrified transportation continues to develop, and options like these deal with the rising want. Microchip’s 10kW compact BLDC motor reference design simplifies the design course of.

The design affords a compact, standalone motor controller answer for BLDC/PMSM motors, supporting peak ranges as much as 10kW and programs as much as 85V. It consists of varied auxiliary connections for sensing and interfacing with the system.

The BLDC Motor Driver Reference Design, with its compact measurement, affordability, and excessive efficiency, is good for up to date e-mobility motor management purposes reminiscent of e-scooters and e-bikes. Furthermore, it will probably additionally function the BLDC motors in high-power drones and UAVs.

The dsPIC33CK256MP505 DSC motor controller affords as much as 3kW of most output energy, with a steady present of 150A RMS and a peak present of 300A for about 120 seconds. It helps an enter voltage vary of 18–85V VBUS, accommodating battery packs as much as 20 seconds in length. It options an XT90-type connector for the battery pack for ease of connection.

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This motor controller employs Subject-Oriented Management (FOC) with HALL sensors (120°/60°) and helps a number of working modes, together with fixed pace, fixed torque, and fixed energy. Superior options embrace Most Torque Per Amp (MTPA) for IPMSM motors and Subject Weakening (FW) to increase the fixed energy vary.

The three-phase inverter stage makes use of three MIC4101 (or MIC4104) 100V half-bridge MOSFET gate drivers and eighteen N-Channel Low RDS(on) MOSFETs (typical 1.7 mΩ), with three MOSFETs in parallel at every place. Present sensing is achieved with three low-side shunt resistors (250 µΩ) per inverter section, and the Pulse-Width Modulation (PWM) switching frequency ranges from 8–20 kHz. 

Built-in protections inside the controller embrace safeguards towards overvoltage and Undervoltage for the BUS voltage, motor section overcurrent, inverter stage overtemperature, and HALL sensor errors. Moreover, the system options regenerative braking functionality. System bias is managed by way of a 12V MCP16331 Buck regulator, a 5V MCP1754S-5 LDO, and a 3.3V MCP1754ST-33 LDO, with temperature measurement supplied by the MCP9700A. The ATA6561 helps CAN communication, whereas an auxiliary connector accommodates throttle enter, voltage monitoring, I2C, UART, Bluetooth, and different features.

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The EeZeeFOC Driver GUI makes motor drive optimization simpler. The controller’s compact dimensions of 20 x 10 x 6 cm make it appropriate for a variety of purposes.

Microchip has examined this reference design. It comes with a invoice of supplies (BOM), schematics, meeting drawing, printed circuit board (PCB) format, and extra. The corporate’s web site has further information concerning the reference design. To learn extra about this reference design, click on right here.