Compact BLDC Motor Reference Design

This design permits for a number of working modes, together with fixed velocity, torque, and energy, making certain flexibility and flexibility in numerous utilization situations.

The demand for compact, environment friendly motor controllers is surging alongside the expansion of micro-mobility units equivalent to e-scooters and e-bikes. These units, pushed by the push for environmentally pleasant and fuel-efficient transportation, require superior management techniques to fulfill the wants of electrification in transportation. A standalone motor controller resolution tailor-made for BLDC (Brushless DC) and PMSM (Everlasting Magnet Synchronous Motor) techniques offers a really perfect reply to this demand. Supporting energy ranges as much as 3kW and voltage inputs as excessive as 85V, these controllers are optimized to fulfill the operational wants of high-performance e-mobility techniques.

The dsPIC33CK64MP105 DSC motor controller design by Mircochip Expertise is designed for top output, providing a steady 50A RMS and peak present ranges of as much as 150A for temporary durations. This functionality permits the controller to deal with excessive calls for with out compromising on effectivity. It options an 18–85V enter voltage vary, appropriate for as much as a 20s battery pack, with an XT90-type connector for fast and safe connections. Based mostly on Area Oriented Management (FOC) with HALL sensors, the system’s management algorithms guarantee exact management over the motor’s torque and velocity.

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Enhanced management options are built-in to optimize efficiency, equivalent to Most Torque Per Amp (MTPA) for IPMSM motors and Area Weakening (FW) for an prolonged energy vary. On the coronary heart of the motor’s energy supply system is a strong three-phase inverter stage. Using three MIC4101 (or MIC4104) 100V half-bridge MOSFET gate drivers and 6 low RDS(on) MOSFETs, this stage minimizes resistance and warmth, maximizing energy effectivity. The present sensing mechanism depends on three low-side shunt resistors (500 µΩ every) positioned on every part, and PWM switching frequencies are configurable from 8 to twenty kHz, giving designers further management over effectivity and noise discount.

For enhanced security, built-in protections are included, equivalent to overvoltage and undervoltage safeguards on the BUS, motor part overcurrent detection, and over-temperature safety on the inverter stage MOSFETs. This controller additionally helps regenerative braking, serving to to enhance general power effectivity. Extra design options embrace system bias era with a 12V buck regulator, in addition to 5V and three.3V LDOs, and temperature monitoring through the MCP9700A sensor.

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To facilitate connectivity and ease of management, the controller is provided with CAN communication, alongside auxiliary connections for throttle enter, voltage monitoring, I2C, UART, and Bluetooth® choices. Moreover, the EeZeeFOC Driver GUI offers an intuitive interface for motor drive optimization. This compact motor controller measures 13 x 7 x 6 cm, making it extremely appropriate for micro-mobility functions the place house is at a premium. This complete, high-power resolution is poised to assist the rising calls for of the micro-mobility market, selling environment friendly, high-performance electrical transportation.

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