tag:blogger.com,1999:blog-37179109061934929432024-02-02T00:37:23.666-08:00Designing Ebike ControllerUnknownnoreply@blogger.comBlogger7125tag:blogger.com,1999:blog-3717910906193492943.post-73797686052041169412015-08-12T02:43:00.001-07:002015-08-26T01:57:49.243-07:00New Battety Technologies<div dir="ltr" style="text-align: left;" trbidi="on">
As we all know, Motor rating is fixed, and only thing that affect the eBike or car range is, BATTERY.<br />
<br />
Yeah, but battery technology improving these days due to intense researchs,<br />
<br />
<br />
<b>Conventional Batteries (we're using, also in production) : </b><br />
Lead acid battery<b> </b><br />
Li-ion battery<br />
Li-ion Cells<br />
LiPo (Lithium ion-polymer)<br />
Li-ion phospate<br />
<br />
<br />
<b>Capacitor type batteries :</b><br />
Ultrabattery<br />
Supercapacitor<br />
<br />
<b>Upcoming (will be launched soon) :</b><br />
<b>EEStor - </b><a href="https://en.wikipedia.org/wiki/EEStor">https://en.wikipedia.org/wiki/EEStor</a><br />
Sakthi3 -<br />
StorDot - <br />
<br />
-----------------------------------------------------------------------------------------------------<br />
<br />
<i>Supercapacitors</i> store 2700 F, and charge in few seconds, but only contraint is weight, 15w-50w/kg<br />
<br />
<i>Ultrabattery</i> Lead acide battery and supercapacitor hybrid is ultrabattery, that is it improve the lifecycle/efficiency of lead acid battery, also improve faster charging/discharing.<br />
<br />
<b>Supercapacitor specification :</b><br />
Maxwell BCAP3000P 3000F 2.7V Super Farad Cap Ultra Capacitor<br />
<br />
Capacitance 3000 farads<br />
DC Equivalent Series Resistance (ESR) 0.29 milliohm<br />
AC Equivalent Series Resistance (ESR) 0.24 milliohm<br />
Leakage Current 5.2 mA<br />
Operating Temperature Range -40°C to +65°C<br />
Stored energy 10944 joules (3.04 WH)<br />
Max Power 3020 Watts<br />
Connections M12 x 1.75 threaded stud<br />
Weight .89 lb (405 grams)<br />
Diameter 2.4 inches (61 mm)<br />
Height (including studs) 6.53 inches (130 mm)<br />
Stud diameter .55 inches (14mm)<br />
Stud height .120 inches (3 mm)<br />
<br />
<br />
Normal Lead acid and Lipo batteries capacity calculated in Ah, V<br />
Capacitors /Supercapacitors capacity calculated in Farad<br />
<br />
Fard to Ah conversion (for theorital understanding only):<br />
<br />
In Lead acid battery, even after discharge, it keep the voltage same, but in capacitor half discharge means, voltage also reduced by half. <br />
<br />
<br />
<br />
<br />
<br />
<br /></div>
Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-3717910906193492943.post-19615064528791017322015-08-11T16:33:00.003-07:002015-08-11T16:33:46.479-07:00Cooling of Motor and MOSFET<div dir="ltr" style="text-align: left;" trbidi="on">
Due to the heavy current flow in Motor stator winding and MOSFET, there is a possibility of damage beyond certain temperature, so we have to cool it to maintain below optimal temperature.<br />
<br />
<br />
This cooling is done in the price of reduced range, yeah we're using the power for cooling equipments from same battery, better we have to use the temperature sensor data to ON/OFF the cooling equipments, if we kept the cooling equipments always ON means, resulting in low range of eBike.<br />
<br />
<b>Which equipmets need cooling :</b><br />
<u>Mosfet</u>, due to high speed switching / regenerative braking / high current flow, the temperature increase suddenly, so we must need cooling.<br />
<br />
<u> Motor stator coil</u>, as we supply the power in the stator coil, due to copper loss/eddy current loss, stator coil temperature also increase suddenly, so we have to keep this also cool. <br />
<br />
<b>Offtopic:</b><br />
High speed (above 40 kmph) reduce the range of
eBike so it drain the battery faster, also it increase the copper
losses at high rpm, so if we kept eBike in optimal speed means, More
range, safety to our equipments too without the need of cooling.<br />
<br />
<br />
<br />
<b>Cooling technique for Mosfet :</b><br />
Air cooling - Simply placing a CPU fans in controller box keep the temperature of circuits under control or within the preset level, Fan is fitted in heatsink, or we have to increase the surface area of heatsink, that is we can easily increase the surface area by placing aluminiu rectangular metal pack, so due to large surface area it grab more heat from the heatsink, and keep the circuits cool.<br />
<br />
Water cooling - <br />
For water cooling, we need to remove heatsink and place the water cooling small equipments, and we have to keep the water flow.<b><br /></b><br />
<b><br /></b>
<br />
<div style="text-align: center;">
---------------------</div>
<br />
<b>Cooling technique for Motor :</b><br />
<br />
Air cooling using CPU Fan - Put a hole in motor case/shield and place the CPU fans there, so it reduce the temeprature of stator coils.<br />
<br />
<br />
Air cooling using Mini compressor - Chinese made mini compressors are available, they're operating at 12V 150W, which are mainly created for small refrigerators in car for keeping beer cans cool, we can use this mini compressor to generate cool air (in range of 20 degress celcius), so it cool the coils.<br />
<br />
Air cooling using mini compressor with Vortex Cool Tool Cold Air Gun Spot Cooler - Spot coolers are popular, as these cool they cool in rapid manner.<br />
<br />
Water cooling - creating a water path, and run by a small pump like we do in cooling engine in car.<br />
<br />
<br />
<br />
<br />
<div style="text-align: center;">
<span style="color: #274e13;"><span style="font-size: medium;"><b>In Progress, Will Update ...! </b></span></span></div>
</div>
Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-3717910906193492943.post-28375836222355240272015-08-08T11:18:00.000-07:002015-08-08T11:55:30.076-07:00Input Stage of BLDC Controller<div dir="ltr" style="text-align: left;" trbidi="on">
Input stage consist of rs232/USB and Microcontroller, we need to connect the rs232/USB to external interface to load the code into microcontroller.<br />
<br />
<b>Input stage :</b><br />
<ol style="text-align: left;">
<li>PCB work</li>
<li>Coding the Microcontroller unit</li>
</ol>
<br />
<div style="text-align: center;">
<span style="color: #274e13;"><span style="font-size: large;"><b>In Progress, Will Update ...! </b></span></span></div>
<ol style="text-align: left;">
</ol>
</div>
Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-3717910906193492943.post-82075551628940009862015-08-08T11:15:00.000-07:002015-08-26T01:56:51.764-07:00Output Stage of BLDC controller<div dir="ltr" style="text-align: left;" trbidi="on">
As output stage of the controller grab the source power (from Battery) and supply to the load (Motor), so i planned to design the Output portion first.<br />
<br />
<br />
<b>Output stage componets :</b><br />
Mosfet<br />
IGBT drivers<br />
Current sensors.<br />
Thick Busbar / Thick Soldering for connecting the Mosfet output to the Motor phase leads.<br />
<br />
<b>Output stage Circuit :</b><br />
Full bridge<br />
Double Puse test.<br />
--------------<br />
<br />
<b>What is MOSFET ? </b><br />
MOSFET is the 3 terminal/lead electronic device, terminals are Source(S), Gate (G), Drain (D)<br />
<br />
Mosfet is just a switch, but it ON only when the Signal/voltage given in Terminal G (gate),<br />
if the gate signal is given to Mosfet, it start conducting that is, it supply the power connected to Terminal S (source) to the Terminal D (drain)<br />
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_W682mrd6QrP-XsUuKOW7QHpNWqZX9_rGakrrnUKRTLB7X-2sbUxF3ahT0Qg9gfVVjEmujSyoiSpNBnzgIPc9cLiQdfKJvHGY9q9eDoMb7cG4mvZRqNDe7OT4N-gkNGVp0cqemVLlW_4s/s1600/7.mosfet_p_type.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_W682mrd6QrP-XsUuKOW7QHpNWqZX9_rGakrrnUKRTLB7X-2sbUxF3ahT0Qg9gfVVjEmujSyoiSpNBnzgIPc9cLiQdfKJvHGY9q9eDoMb7cG4mvZRqNDe7OT4N-gkNGVp0cqemVLlW_4s/s1600/7.mosfet_p_type.png" /></a></div>
<div style="text-align: center;">
P type Mosfet Symbol </div>
<br />
<br />
<br />
<div class="separator" style="clear: both; text-align: left;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgim3NnzDdkZ1VSv4ghnEZBw4iD_WysOQMjiYsHcYcze8U1Of0t2mxTURhaLPKj3g_1gPtyhjK0HzGrzQeRJ0CiBmFBRCPDa0drjk-ZBJ3yf9_R2RngYvBBtbI3rKx7aRyCf9Wh54IvRE6r/s1600/8.mosfet.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgim3NnzDdkZ1VSv4ghnEZBw4iD_WysOQMjiYsHcYcze8U1Of0t2mxTURhaLPKj3g_1gPtyhjK0HzGrzQeRJ0CiBmFBRCPDa0drjk-ZBJ3yf9_R2RngYvBBtbI3rKx7aRyCf9Wh54IvRE6r/s1600/8.mosfet.png" /></a></div>
<div class="separator" style="clear: both; text-align: left;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiatEBDU6fp83B6B34aS2hlFJcjxhdmz26Cp5ozScrMTho0sfCUwrAWYrly8Q4TVTa6EjzXeUsGEhS8wmXIVT4L84DqHWR2XcZnlRGEb-bin13ESq9VGLXLXciADEgy-U_zmoCr8TOclHK3/s1600/8.mosfet.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><br /></a></div>
<br />
Figure shows Terminal 'S' connected to Battery, Terminal 'D' connected to Motor phase, Terminal 'G' connected to IGBT driver<br />
<br />
<br />
<br />
<b>Example :</b><br />
Battery is connected to the Terminal S (source) of MOSFET,<br />
Motor is Connected to the Terminal D (drain) of MOSFET,<br />
IGBT Driver is connected to the Terminal G (gate).<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_-XFpmEEuMKMlhVRBKqQd4p7JJdajWWHDid3Olrj45cOcX4NZTIJtQrKoiBWeJdxC9-HNF0kz6N-O9EEl1qSR3qDH-qhMCc9htbVGjAnAG7e_3ktcIYbVqnplnXkb1GUICyklb9yfNzw3/s1600/9.mosfet.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="442" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_-XFpmEEuMKMlhVRBKqQd4p7JJdajWWHDid3Olrj45cOcX4NZTIJtQrKoiBWeJdxC9-HNF0kz6N-O9EEl1qSR3qDH-qhMCc9htbVGjAnAG7e_3ktcIYbVqnplnXkb1GUICyklb9yfNzw3/s640/9.mosfet.png" width="640" /></a></div>
<br />
<br />
[ON] Once the Signal/Voltage from IGBT Driver is given to Terminal G, Current flow occurs from battery to Motor.<br />
<br />
[OFF] If no signal/voltage given from IGBT Driver to Terminal G, <b>NO</b> Current flow occurs from battery to Motor.<br />
<br />
<br />
<b>Practical Mosfet :</b><br />
theoritically, if we removed or stopped the supply to the Terminal G (gate), then terminal S (source) to Terminal D (drain) become open (no conduction), but this is not happening preactically, see the below video<br />
<br />
<a href="https://www.youtube.com/watch?v=UwzepcZQyQc">https://www.youtube.com/watch?v=UwzepcZQyQc</a><br />
<br />
For ON we need to give signal/supply to the Terminal G, for OFF even after removal of gate signal still MOSFET conduct, so we need to ground the Terminal G, then only it stop conduct.<br />
<br />
<br />
<b>How many FET going to use ..??</b><br />
It is one of the important question regarding controller. In single controller we're going to use "Full Bridge" circuit, so the numbers must be like 6, 12, 18, 24 FET (multiples of 6 is the simple rule).<br />
<br />
I planned to use 6 FET for my controller, as it is the minimum one.<br />
<br />
<br />
Per MOSFET power dissipation :<br />
<br />
<br />
MOSFET name and number :<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<i><b>Current Sensor :</b></i><br />
Once we accelerate the bicycle using throttle, then the current flow increases, sometime it may damage the controller and motor, as they have certain limit, if it crossed the limit, then they damage, so we have to measure the current flow in phase wires (between controller and motor), and using the current sensor, and supply the measured current value to microcontroller, as we already store/programmed the certain current limit, so microcontroller compare the realtime current flow in phase wires with the preset limiting value, if it cross the preset current limiting value, then Microcontroller stop the signal to MOSFET, once the current flow value is below the preset value then it automatically turn ON.<i><b><br /></b></i><br />
<br />
<br />
<b>Buck Converter :</b><br />
BLDC motor is powered by battery in which controller sits in center between baatery and motor, but electronic components in controller also need a electric supply (in few 5v to 12v), so to stepdown the volatage we need a Buck converter.<br />
<b> </b><br />
<br />
<b>Double Pulse Tester :</b><br />
To know the switching characterisitics of MOSFET for our setup, we need to do one test called "Double Pulse Test", using this test we can understood more about the MOSFET temperature for certain current value and all, it is something like simulation without original load (motor) <br />
<br />
<br />
<br />
------------<br />
<br />
<u><b>Choosing the Components :</b></u><br />
<br />
<br />
<b><i>MOSFET Choosing :</i></b><br />
Choosing MOSFET for controller depends on peak current and peak voltage, if we used the less rating MOSFET means, due to power dissipation overheat, it simply burns, so we always have to choose the higher rating MOSFET.<br />
<br />
<b><i><br /></i></b>
IRFP4110 - 100 A , 100 V, <a href="http://www.irf.com/product-info/datasheets/data/irfb4110pbf.pdf" target="_blank">Download datasheet</a><br />IRFP4468 - 190 A , 100 V, <a href="http://www.irf.com/product-info/datasheets/data/irfp4468pbf.pdf" target="_blank">Download datasheet</a><br />
<br />
We can decide from above mosfet ratings, still lot of high rating mosfets are there for higher power vehicles like car/bus/truck, but thing is higher power MOSFET need a proper cooling.<br />
<br />
<br />
<br />
<i><b>IGBT Driver Choosing :</b></i><br />
<br />
<br />
<br />
IRS2186 - <i><b><br /></b></i><br />
<br />
<br />
<i><b>Current Sensor choosing : </b></i><br />
<br />
ACS758 -<br />
<br />
<br />
<b>Buck Converter choosing :</b><br />
<br />
LTC3638 - <br />
<br />
<br />
<div style="text-align: center;">
<i><b><span style="color: #274e13;"><span style="font-size: large;"><b>In Progress, Will Update ...! </b></span></span></b></i></div>
</div>
Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-3717910906193492943.post-27846713514360703442015-08-06T17:14:00.000-07:002015-08-16T00:06:20.843-07:00Choosing the Motor and Battery for controller design<div dir="ltr" style="text-align: left;" trbidi="on">
For designing the controller, we need the motor rating and battery voltage.<br />
<br />
<b>Requirements :</b><br />
Speed : 40-50 mph.<br />
Battery undervoltage Protection :<br />
Current Limiting :<br />
Method : PWM (Pulse Width Modulation)<br />
Assumption : 30-35 Wh per Mile. <br />
Motor : 48V 2000W<br />
torque : (still dont know how much i need, have to study) <br />
<br />
<b>For calculating rpm (still have to analyse):</b><br />
https://endless-sphere.com/forums/viewtopic.php?f=28&t=16114<br />
http://www.algebra.com/algebra/homework/Rational-functions/Rational-functions.faq.question.501480.html <br />
<br />
<br />
<b>Motor rating </b>: 48V 2000W , Sensored<br />
From videos seen in youtube, 2000W or 3000W BLDC motors are doing good speed, but as this is my first project so i choosed 2000W, as our area have big slops/terrain.<br />
<br />
<br />
<b>Choosing Battery :</b><br />
There are 2 choices in battery 'Li-ion cells' and 'Li-ion Polymer',<br />
but Li-ion Polymer have lot of advantage over Li-ion batteries, like less weight, quick charge, high discharge current comparing to Li-ion cells battery,but in price point of view Li-ion cells are cheaper.<br />
<br />
<b>Li-ion cells :</b><br />
Li-ion batteries are available in big block shape (we're using that in home UPS system) and Li-ion Cells<br />
Tesla cars even use Li-ion cells.<br />
<br />
<b>Li-ion Polymer (LiPo) :</b><br />
Lithium ion Polymer (LiPo) batteries are used for Ebikes mostly due to it's high peak current, Li-ion batteries are specified in 'C' and 'S' Value,<br />
<br />
<b>C</b> means, <b>Continuous, </b><br />
if battery show 40C means, we can grab maximum 40 A continuously.<b></b><br />
<b><br /></b>
<b>S</b> means, <b>Series, </b><br />
If battery shows 3S means, 3 cells are connected in series, that is 3.7 V x 3 cell = 11.1 v .<br />
Li-ion Polymer battery is created by series joint of cells, each cell voltage is 3.7v<br />
<br />
<b>mAh means, milli Ampere hour,</b><br />
If battery shows, 4000 mAh means, its capacity is 4000 mAh or it can store 4000 mAh. <br />
<br />
<br />
<b>Example :</b><br />
<i>Battery Specififcation :</i>16 Ah 22.2V <br />
<br />
<b>For more detailed thing about battery (highly useful) :</b><br />
http://www.rchelicopterfun.com/rc-lipo-batteries.html<br />
http://www.rchelicopterfun.com/rc-battery-chargers.html<br />
http://www.hobbyking.com/hobbyking/store/uh_viewitem.asp?idproduct=6589&aff=143580<br />
<br />
<b>Battery Fuse :</b><br />
http://infectedarmory.com/product/self-resetting-fuses/<br />
<br />
<br />
<b>Budget wise :</b><br />
High budget (use LiPo), Low budget (use Li-ion cells)<br />
<br />
<br />
<br />
<b>Range Calculator :</b><br />
Range is one of the important factor to consider in creating an ebike, if we use ebike for home to office, then back to home. we have to calculate the per day usage kilometer or Miles, and adding extra Kilometer, so we may use it for other works too.<br />
<br />
Eg :<br />
Home to Office distance = 10 Miles (16 Km) , to and fro distance is 20 Miles, so we have to create ebike range greater than 20 Miles, say 25 or 30 miles will be better .<br />
<br />
<br />
<br />
<b>Range</b> = Number of batteries x Capacity of single battery (in Ah) x Voltage of single battery (in V)<br />
___________________________________________________________________<br />
Per Miles Watt usage<br />
<br />
<br />
<br />
<b>Per Miles Watt usage</b> vary depends on speed, so we have to assume it as 35-50 Watt per Miles<br />
<br />
<br />
Eg : <br />
So assume Per watt Miles as 40 watt<br />
i have 5 batteries of 26000 mAh , 22.2V ,<br />
convert 26000 mAh to Ah, just divide by 1000, so 26 Ah.<br />
<br />
<b>Range</b> = 5 x 26 x 22.2 <br />
_____________<br />
40<br />
<br />
= 72.15 miles<br />
<br />
according to your need, you can increase or decrease the number of batteries.<br />
<br />
<br />
<b>Weight </b>:<br />
For Low weight (use LiPo), weight is not a matter (use Li-ion cells)<br />
<br />
Example<br />
if we're going to use in <i>bicycle/motorbike/car</i> means, little extra weight is not going to affect a performance, so Li-ion cells is enough, still LiPo give less weight.<br />
<br />
but if you're going to use in <i>helicopter/mini aeroplane/Drone</i>, then weight matters, so LiPo is the only choice.<br />
<br />
<br />
Example :<br />
For Li-ion Polymer , 16000 mAh 6S1P 22.2V - Weight : 1932 gram.<br />
<br />
think i am using 3 batteries,<br />
3 battery total capacity in watt = 3 x 16 x 22.2 = 1065.6 W = 1.065 kilowatt<br />
<br />
3 battery weight in gram = 3 x 1932 gram = 5796 gram = 5.796 kilogram.<br />
<br />
so 5.796 kg battery store 1.065 kw,<br />
<br />
<b>1 kg of LiPo batteries store = 1.065/5.796 = 0.1834 kw </b><br />
<b>1 kw of Lipo batteries weight = 5.796/1.065 = 5.442 kg</b><br />
<br />
<br />
<b>Now same calculation for Li-ion cells.</b><br />
For Samsung ICR18650-26F cells , 2600 mAh, 3.7V - Weight : 48 gram.<br />
<br />
<br />
think i am using 110 cells,<br />
110 cells total capacity in watt = 110 x 2.6 x 3.7 = 1058.2 W<br />
110 cells weight in gram = 110 x 48 = 5280 gram<br />
<br />
so 5.280 kg of cells store 1.0582 kw<br />
<br />
<b>1 kg of Li-ion cells store = 1.0582/5.280 = 0.20 kw</b><br />
<b>1 kw of Li-ion cells store = 5.280/1.0582 = 4.989 kg</b><br />
<br />
<br />
but thing is packing of 110 cells need a special battery pack, have to weld, and connecting wires, charging of this 110 cell, these constraints increase the overall weight of the battery pack, resulting in LiPo the winner in weight range.<br />
<br />
<br />
<span style="color: blue;"><b>What i choosed :</b></span><br />
16000 mAh 6S1P 22.2V<br />
http://www.genstattu.com/ta-15-16000-6s1p.html<br />
<br />
<br />
<br />
<b>Range</b> = 1 x 16 x 22.2 <br />
_____________<br />
40<br />
<br />
= 8.88 miles<br />
as i use very less, so choosed only single battery.<br />
<br />
<br />
===========<br />
<br />
<br />
<br />
<br />
<br />
<b>Number of cells/power needed :</b><br />
<br />
<br />
<b>Li-ion cells 18650 2600 mAh 3.7V : </b><br />
Theoritical calcualtion :<b> </b><br />
10s 10p = 26.0A 37.0v, 0962.00W, 4800 gram, 100 cells.<br />
11s 11p = 28.6A 40.7v, 1164.02W, 5808 gram, 121 cells<br />
12s 12p = 31.2A 44.4V, 1385.28W, 6912 gram, 144 cells<br />
Practical values :<br />
<br />
<br />
<br />
<b>Li-ion cells 18650 6000 mAh, 3.7V :</b><br />
<br />
10s 10p = 26.0A 37.0v, 0962.00W, 4800 gram, 100 cells.<br />
11s 11p = 28.6A 40.7v, 1164.02W, 5808 gram, 121 cells<br />
12s 12p = 31.2A 44.4V, 1385.28W, 6912 gram, 144 cells <br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<div style="text-align: center;">
<span style="color: #274e13;"><span style="font-size: large;"><b>In Progress, Will Update ...! </b></span></span></div>
</div>
Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-3717910906193492943.post-49902551682088753112015-08-06T15:18:00.001-07:002015-08-09T07:34:46.708-07:00Designing an Ebike BLDC Controller from Scratch<div dir="ltr" style="text-align: left;" trbidi="on">
hi guys,<br />
i am noob in this field, planned to design Ebike controller from scratch , why i choosed Controller is, because controller is the heart of the ebike, other parts can be bought easily with our needs, but controller is costly and most doesn't fullfil our needs.<br />
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First i try to understand the controller and its components, without knowing the details and starting a PCB work is like learn swimming in centre of the pacific ocean, so i am always try to explain everything in brief, so noob like me can easily understood.<br />
<br />
<b>Name :</b> 6 FET BLDC Controller <br />
<b>Target :</b> Simple Ebike controller for BLDC motor (Brushless DC motor)<br />
<b>Motor :</b> 48V 2000W<br />
<b>Battery :</b> 1 x 10000 mAh 6S1P 25C 22.2V<br />
<br />
<b>Deadline :</b> 1 year (within August 2016)<br />
<br />
<blockquote class="tr_bq">
From my view, Ebike controller or Controller for BLDC is common to all, example if we developed one model successfully then we can use it in ebike, cycle, motorbikes, car and lot of application, so we have to progress slow and steady.</blockquote>
<br />
Google helped me a lot, and what i understood is, Controller consist of input and output.<br />
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Below figure show the components which connect to controller. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtFJoXpLip6i3IvMQ6piokahM5BMC5nlWCKq32OKU5ac3bxwt7oLTe0bryGiD3LAVWlN9v03AkM37RX8pjInB0dL628PTRbPTxtaZ8KSxTaJF8sTF-XZCl7-LuDOs6fL0RTAbvxddOx6Hy/s1600/img1.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtFJoXpLip6i3IvMQ6piokahM5BMC5nlWCKq32OKU5ac3bxwt7oLTe0bryGiD3LAVWlN9v03AkM37RX8pjInB0dL628PTRbPTxtaZ8KSxTaJF8sTF-XZCl7-LuDOs6fL0RTAbvxddOx6Hy/s1600/img1.png" /></a></div>
<b>Throttle :</b> we increase/decrease the ebike speed using the throttle , which is connected to input of Controller.<br />
<b>Cycle Analyst :</b> it display the speed, temperature of motor, current values, which is connected to input of the controller. (because temperature of motor are got from tememperature senor, which is connected to input of controller)<br />
<b>Battery :</b> it supply the power to the motor, which is connected to the output of the controller<br />
<b>Motor :</b> it is the load, sensorless 2000W BLDC<br />
Temperature sensor : it have to be fitted inside the motor, so we can view the temperature of motor in cycle analst display<br />
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<b>Image 2 : </b><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqn00t5x8GLfdTidQj5We4AG7sAy6UGifDcGmcC5QIvLk4QzuiSGgkh2EkIxOl-SCsMsbF-isQoI5ur4DnwtP3xenhq3vOehnWm5U-CnuoU1LImgvM0aoVe3f0NpcuVJxVT1iT_y4qHjjR/s1600/img2.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="474" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqn00t5x8GLfdTidQj5We4AG7sAy6UGifDcGmcC5QIvLk4QzuiSGgkh2EkIxOl-SCsMsbF-isQoI5ur4DnwtP3xenhq3vOehnWm5U-CnuoU1LImgvM0aoVe3f0NpcuVJxVT1iT_y4qHjjR/s640/img2.png" width="640" /></a></div>
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BLDC Motor consist of 7 wires, they're<br />
3 wires for phase,<br />
3 wires for hall sensor,<br />
1 for temeprature sensor we fitted in it. <br />
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3 hall sensor wire and 1 temperature sensor wire is connected to input of controller.<br />
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Imgae 3 :<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5U9I0bOL10PgZt8y7AdCa1gQsCueIAIEhyszqj0jQ5I4Yb2UqxixAqRi8zbK3TAHudvDP-y_OABWhRp4jKe3n7F-Y43b8lMKByHMpuV_PxWP3SRaX8ovODEF6fXlYGGvqlMAwDuRxf2JU/s1600/img3.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="482" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5U9I0bOL10PgZt8y7AdCa1gQsCueIAIEhyszqj0jQ5I4Yb2UqxixAqRi8zbK3TAHudvDP-y_OABWhRp4jKe3n7F-Y43b8lMKByHMpuV_PxWP3SRaX8ovODEF6fXlYGGvqlMAwDuRxf2JU/s640/img3.png" width="640" /></a></div>
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In above figure, all 3 pahse wires of motor (U, V, W) is connected to the output of the controller, as current flow in both direction because of regenerative braking, so we used the double side arrow.<br />
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Image 4 :<br />
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In above image, battery is connected to the output of the controller.<br />
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<b>Image 5 :</b><br />
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in above image, throttle is connected to the input of the controller, and cycle analyst is connected to the controller.<br />
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<b>Image 5.1 :</b><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh492-amhwwnrUDD4QKhTWFXZGmb4jbfCwVA1a7HK5r1NoBvcWC5lXBJmBtHj-_sXPoLSBG6Y5EpO12-84UhuyE3FP3-dtCr8jNTLLE0pnU7Gj_TtdCFvgycbMkeWCmFBckxzUbTXxEB0kF/s1600/img5.1.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="442" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh492-amhwwnrUDD4QKhTWFXZGmb4jbfCwVA1a7HK5r1NoBvcWC5lXBJmBtHj-_sXPoLSBG6Y5EpO12-84UhuyE3FP3-dtCr8jNTLLE0pnU7Gj_TtdCFvgycbMkeWCmFBckxzUbTXxEB0kF/s640/img5.1.png" width="640" /></a></div>
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Brake signal or voltage needed for regenerative braking, so it must connect to the input of controller and fuse (between controller and battery) is must to protect the controller and motor from overcurrent.<br />
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Till now i understood about the components of ebike and its connections, now let us move to the controller.<br />
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-----------------<br />
After lot of search on goolge and read from lot of sites i understood few more things about controller.<br />
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In Electronics they're two type of devices/components<br />
1) Active device<br />
2) Passive Device<br />
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Active Device change the signal/current by amplification. example : transistors, op.amp<br />
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Passive devices change the signal/current by attenuation. example : resitor, capacitor, inductor.<br />
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still i not understood lot of these, but i will try to learn and post here, so it may helpful for others.<br />
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Here In our schematic, we discuss about "Active devices" only first, once we finalised the active devices, then we have to find a way for passive devices and values.<br />
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<b>Image 6 :</b><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRcKvAUQLtMzoDGOtiS_hWiFXq4lKMqKkeVrpyrwqxQur7qU5m4XRN6nsuHuXbrpPkiaZs3f7Br1s0IkxVdSCD9TZy3PPtpuukCu7ncgdJ-E9OYYmlG5dXihFLLRcJTm9SCGBFbvRAa_8v/s1600/img6.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="360" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRcKvAUQLtMzoDGOtiS_hWiFXq4lKMqKkeVrpyrwqxQur7qU5m4XRN6nsuHuXbrpPkiaZs3f7Br1s0IkxVdSCD9TZy3PPtpuukCu7ncgdJ-E9OYYmlG5dXihFLLRcJTm9SCGBFbvRAa_8v/s640/img6.png" width="640" /></a></div>
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<span style="color: red;"><b>Controller input unit :</b></span><br />
Input unit consist of rs232/usb and microcontroller. <br />
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<b>Microcontroller :</b><br />
Microcontroller process the hall sensor input data we given and give signal to MOSFET through IGBT Drivers.<br />
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<b>rs232/usb :</b><br />
Microcontroller process any amount of data, but for processing we need to program the microcontroller, for that we have to connect rs232/usb to computer or some external interface to load the program codes into the microcontroller.<br />
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<span style="color: red;"><b>Controller output unit : </b></span><br />
Contrller output consist of IGBT drivers, Mosfets, Current sensor.<br />
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<b>Mosfets :</b><br />
Mosfets is just a switch , but it can switch at a speed of 20 khz and above.<br />
Battery and BLDC motor is connected through Mosfet that is, mosfet control the voltage/current flow from battery to Motor by switching. (we call as switched mode power supply). When to switch ON and when to switch OFF the Mosfet was guided by Microcontroller through the IGBT drivers .<br />
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<b>IGBT driver :</b><br />
https://en.wikipedia.org/wiki/Gate_driver<br />
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Microcontroller decide when to switch ON and OFF the MOSFET and give signal, but the signal current is very low in milliampere (mA) so if we pass the microcontroller signal directly to MOSFET means, due to low signal current, MOSFET switching speed will be very low and switching loss become high, so we use the intermediate circuit called "IGBT Drivers" to amply the current , and then given to the MOSFET, so MOSFET work smoothly in high switching speed.<br />
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<b>Current Sensor :</b><br />
If the output current from MOSFET crossed certain limit means, Motor will burn or MOSFET will burn, so we have to limit the current values. For limiting the current value first of all we must know the exact current flow through the MOSFET , so we need a current sensors, which give signal to the Microprocessor, which compare the current wuth pre-set value, if it crossed the pre-set value it shutoff the MOSFET, once the current value in less then the pre-set value the it automatically on the MOSFET.<br />
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First i planned to start output portion of controller, because Input portion is related to coding, but without the values of output stage we wont code, so i am starting from output portion.<br />
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<div style="text-align: center;">
<span style="color: #274e13;"><span style="font-size: large;"><b>In Progress, Will Update ...! </b></span></span></div>
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Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-3717910906193492943.post-24966219585564904232015-08-06T15:06:00.002-07:002015-08-10T13:01:25.860-07:00Welcome to Ebikecontroller<div dir="ltr" style="text-align: left;" trbidi="on">
hi,<br />
i am very new to this ebike field, due to my own interest i started to thinking about ebikes and planned to create controller from scratch.<br />
<br />
<div style="text-align: center;">
<span style="font-size: large;"><b>My learning things about controller is <span style="color: red;">Documented</span> in this blog fully, so please read all posts. it will surely help newbie to understand controller.</b></span></div>
<br />
<br />
<b>How the interest came ?</b><br />
I am from India and always i try the new technologies, just like that TVS (one of motorbike company in india) announced about launching "TVS Qube", but more than 3 years, they not launched it.<br />
<br />
TVS Qube is a hybrid 2 wheeler (scooter) which work on petrol as well as electricity stored in battery, i dreamed it to buy one, but that delay caused me to think "whyn't you can develop one ..??" then i started searching in internet about hybrid and electric ebikes, this way i concentrated more on eBikes in my free time.<br />
<br />
After a small research, i planned to build eBike (bicycle with electric powered one wheel), that is we have to replace rear wheel by hub motor fitted wheel.<br />
<br />
<b>Parts needed for Ebike :</b><br />
<ol style="text-align: left;">
<li>One Cycle (mountain ranger or one with good front/back suspension is needed)</li>
<li>48V 2000W BLDC Hub Motor (with sensor)</li>
<li>Rear rim with high gauge spokes (we have to Lace the hub motor in it) and Tyre.</li>
<li>Lipo Battery (2 nos)</li>
<li>BMS (Battery management system) so we can charge battery</li>
<li>Throttle (to control the present speed like we do in bikes)</li>
<li>On/Off Switch</li>
<li>Cycle analyst (that display speed/battery current/temeperature and all) </li>
<li>Controller.</li>
</ol>
<br />
<br />
i thought, we can buy this and assemble it, finish, but here the problem start, we can buy everything, except controller, because all the controller available here are only for 250W BLDC motor, but i planned to create for 2000W, so if i got the controller means, Project finished, but controller...????<br />
<br />
thats why i created this blog about creating controller from scratch, i planned to use my free time for creating the controller circuit. <br />
<br /></div>
Unknownnoreply@blogger.com0