TIIC 2016 North America: Three Phase AC Motor Controller


University: Rochester Institute of Technology
Team Members: Matthew Behlke, Samuel Carlson, Derek Gutheil, Adam Hirsch, Joseph Kubeck,
TI Parts Used:

  • CSD19505
  • TMS320F28069M
  • DRV8301
  • SN74LV1T34
  • LM3940

Project Description

A working 3-phace AC controller is required by the Electric Vehicle Team's E-Bike (Later to be modified for the super bike). Currently, the 3-phase AC controller is very power hungry during operation and sub-optimal in performance. Further, it does not allow for regeneration of the batteries during braking. Ideally the new controller will integrate with the current system - allowing both controls and data monitoring to occur as usual (current). The controller will provide high output power and a high degree of control (resolution) of the power train. Finally, the device should be robust and especially durable for race conditions.

The goals of this project are to analyze the system that is currently in existence for such controls. The device should be designed, working, and installed by ImagineRIT in the Spring of 2016. Regenerative battery recharging while braking is a feature that would be ideal to have when the project is complete. The constraints of this project are the budget of $1000 as well as making sure that the controller does not have too strict of optimal condition bounds which would lead to it being too fragile to use for racing. Additionally, the prototype should fit within the current housing constraints. The motor controller should also be compatible with the current subsystems of the E-bike.

More Info

Features
  • Control of Three Phase AC Motor
  • Sensorless Field Oriented Control (FOC)
  • Heat Monitoring
  • Auxiliary 5.5V and 3.3V sources

Resources

All design files (code, schematic, PCB, and BOB) are located in the attached zip file.

User's Guide

The Electric Vehicle Team at the Rochester Institute of Technology has a need for an upgraded three-phase AC motor controller.  This motor controller should improve upon the features, precision, and control of the currently used and outdated board.  The new board is modular so that only minor hardware changes are needed before it can be used on the Rev1 racing electric motorcycle which has higher power requirements. The need for the motor controller to be scalable is a consideration that is very important to the electric vehicle team.  The design will allow for parts to be upgraded for high power.  This was the driving factor for self-designing the PCB.  By doing so P16261 will know exactly which components must be replaced and can pass this information along to the electric vehicle team. One of the largest motivations for doing this project was to provide the electric vehicle team with a motor controller that interfaces with their communication systems.  By doing this it was possible to link the motor controller to the data acquisition system. This allows the team to have full control over the motor controller and to analyze its performance and adjust when needed.