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Why are there 3 ADC0 event Mux trigger sources possible for 3 PWM modules but the PWM generator triggers are tied together?

Guru 55963 points
Other Parts Discussed in Thread: INA282, DRV8301, EK-TM4C1294XL, LM3S8971, TM4C1294NCPDT

LM3S, TM4C processors with PWM generators

Seems odd there are 3 ADCEMUX event trigger sources for 3 separate PWM modules in each Sequencer. Any single one ADC event trigger source will work with the PWM module having all 3 ADC triggers enabled. However when all 3 trigger sources are configured in the ADC SSIO Event Mux for different FIFO sequencers the ADC breaks down and will not sample.

The ADC event trigger sources for each sequencer use the word PWM module 0-2 making it sound as if there are more than one PWM module when in fact there are 3 generators in the entire PWM module of the M3 MCU. The 3 generator triggers are illustrated being tied together in the PWM module. The word module in this context infers a container or vessel which the LM3 Stellaris PWM data sheet text uses to infer the generator as well. TM4 datasheet text makes an effort to distinct the entire PWM module from the individual generator.

If the PWM module generators triggers are all tied together as a single trigger why are there now 4 PWM modules in the TM4C ADC0 event trigger Mux when only one is valid?

The HWREG configuration 3 event triggers are enabled for the PWM generators 3 triggers stops all sampling. Why is 0xE reserved in the M3 when there are the same valid bit assignments in each of the SSIOX events trigger sources?

  • Hello BP101.

    What makes you believe that in TM4C all the 4 PWM generators are tied together?

    Regards
    Amit
  • Hi Amit,

    Lets agree then the individual triggers are not all tied together into one PWM module signal being Fig23-1 does say (triggers).

    Then should not the ADCEMUX in any single sequencer (EM0-EM4) be capable to MUX any single or multiple PWM generator output triggers into one dedicated sequencer trigger? That action OR's 3 triggers into one output as a mux would do in any single sequencer FIFO capable to select any logical combination of the named sources in any single or multiple EMx bit sets. 

    If we program 3 PWM generator trigger sources separately ADCSequencerConfigure() only the last trigger source (PWM2) is actually being programmed and triggers samples as expected. That confirms PWM GEN0 is not the only trigger (PWM0INTEN) source possible in any single or perhaps multiple bits EM0-EM4. Yet when we HWREG mux 3 PWM generators (shown above) into EM0 or EM1 the ADC stops sampling for the LM3, not so sure about the TM4C.

    Was combining 3 PWM generator triggers into a single FIFO not supported on LM3 and now is on TM4C, if not why not?

     

  • BTW:

    Tivaware is doing the same thing Stellarisware was doing by configuring only the last ADCEMUX entry. Even OR'ing the 3  trigger sources in one statement in Stellarisware set the EM0/EM1 to 0xf trigger always. The reason to use HWREG forcing an ( |= ) in the same EMx FIFO bits.

  • Hello BP101

    A single sequencer can have only one trigger source and not a combination.

    Regards
    Amit
  • Hi Amit,

    I see that is the case yet makes very little sense as each PWM generator load pulse can trigger a sample yet we are being asked to sacrifice three sequencer FIFO's to monitor 3 independent triggers. Surely TI is aware that is simply ridiculous to even consider as each FIFO is a precious commodity.

    When there exists a 60-120 degree electrical angle phase shift among each generators gated drive outputs on the control block odd things occur. Some how each generator needs to trigger a sample on load count match. It seem 3 phase trapezoidal wave forms suffer in that phase shift not following the actual current in real time and MOSFETS often take the hit. Other words it seems there are milliseconds of dead time in current management schema as a result of gating PWM asynchronously to load count match from only PWM generator 0. Perhaps it would actually be better to some how trigger ADC samples when the control block outputs gate each generators PWM pulses.

    Any idea how the TM4C might accomplish that mission with a timer or GPIO port as the ADC triggers samples for each PWM generators output?
  • Hello BP101,

    The FIFO has been designed for multiple design scenario and not just motor control. If the intent is on capturing the Analog channel on 3 phases then it must be each PWM, then one solution would be pass the generator trigger to each of the sequencer with only one element for conversion. This would be the closest to a single sequencer with multiple entry (one for each trigger) as in independent single step sequencer mode the operation would be identical.

    Regards
    Amit
  • Hi Amit,

    >The FIFO has been designed for multiple design scenario and not just motor control

    Motion control is boasted feature of the TM4C yet the architecture of the PWM/ADC peripherals is bottle necked at the ADCEMUX. Suppose we want to generate 3 phase DC to AC inverters using 3 PWM generators, each 120 degree phase angle. Again 3 sequencers of the 4 total in either ADC peripheral must be sacrificed since the ADCEMUX is bottle necking the sequencer. Seemingly that is what steps are for so the sample window can follow the source with as little interruption as possible in near real time. Reprogramming the same sequencer repeatedly for a different generator trigger source is time consuming and seemingly invites mayhem. Yet that may be the most effective way to use the same sequencer with 3 PWM generators in the present TM4C architecture.

    Have read your idea a few times but seem to get lost in how the ADCEMUX can be set to trigger from 3 PWM generators using only one sequencer. The scenario infers all the other sequencers are occupied, only one sequencer exists for 3 generators load count triggers.

    Another solution may be to reprogram the ADCEMUX for the same sequencer each time the PWM generator changes. A zero count interrupt handler for each generator can reprogram the ADCEMUX so the load count trigger is ready at top center of load count. That would give some settling time in the ADCEMUX before reaching the top of count. That as well may be plagued by current phase angle issues if the PWM output control block is driven by an source such as Halls or sequence reload timers. Another idea uses an edge count timer that follows each PWM generator B output pin triggering an interrupt handler routine reprogramming the ADCEMUX in sync with the actual (gated) generator pin event versus the free running PWM load count events. Relying on PWM (load count) triggers solely for ADC samples seems to me where the problem of following exact current phase angle is being introduced.

  • Hello BP101,

    A single sequencer cannot have 3 triggers at the same time to fill the FIFO.

    (a) Manually change the Trigger Source
    (b) Set up 3 sequencers with a single step and each sequencer for one trigger source. The third sequencer generates an interrupt and on it's interrupt the other 2 sequencers are read out.

    Regards
    Amit
  • Hi Amit,
    Agree yet the generators outputs and load count triggers are sequentially ordered and do not ever overlap. So a single sequencer will start sample by what ever the ADCEMUX is programmed. Is there some know issue with reprogramming the ADCEMUX on the fly?
  • Hello BP101

    If the ADC Sequencer is Idle then it does not have an impact for on the fly programming. it would be good to check for Idle Status, disable the ADC Sequencer, change the trigger and re-enable it.

    Regards
    Amit
  • Hi Amit,

    In this case the sequencer would be dedicated to the PWM trigger purpose and roughly 80us exist between PWM pulses.
    Was going to say before using an edge count timer to use 3 GPIO single pin interrupts following each generators B output for rising edge event to reprogram the ADCEMUX for the real time event.
  • Hello BP101,

    As I said, the timing of the trigger and the idle state of the ADC need to be ensured as monotonic. No interrupt that may cause disruption of the reprogramming.

    Regards
    Amit
  • Hi Amit,

    Are you referring to the sequencer interrupt being monotonic or the entire ADC peripheral which may have other sequencers interrupting for other processes during ADCEMUX reprogram?

    Each of the 4 ADCSSEMUXn exist at a individual level in architecture, Fig 15-2 of the individual sequencer interrupt level.
  • BTW : It occurred to me when trigger source is GPIO (0x4) the ADCEMUX does not have to be reprogrammed. Question is can the same SSIOx interrupt be assigned to each GPIO pin or will it require port wide interrupt.
  • Hello BP101,

    The ADC Busy Status is for all the sequencers. So if the bit is set then ADC is converting but we do not have an info on which Sequencer it is. So let us assume a case where the Sequencer is idle and we have to change the trigger source. We check the idle bit and are about to change the trigger source. Now an external interrupt causes the CPU to branch to a interrupt handler. When it returns to the change of trigger source, the trigger is has happened for the original source and we change the trigger to new source. The interrupt from the sequencer shall fire and the CPU may be misled to believe that the data is from the new source instead of the old source.

    Regards
    Amit
  • Hello BP101

    What is "SSIOx interrupt"?

    Regards
    Amit
  • HI Amit
    Referring to the sequencer ACEMUX connection to the external corresponding GPIO interrupt.
  • Hello BP101

    You mean the GPIO Trigger to the ADC. All the GPIO Triggers are OR-ed together to generate a single Trigger to the ADC,

    Regards
    Amit
  • Hi Amit

    >The ADC Busy Status is for all the sequencers.

    Makes it sound as if reprogramming the ADCEMUX trigger source on the fly is not without out effect and causality in the mix. After some thought your excellent guidance it seems GPIO source trigger is closer to the actual current event than are the PWM gens load trigger. So when ever the gens B pin rise on the PWM control block the GPIO interrupt source will trigger a monotonic sample in phase with real time current ramps. That madness was not even possible in the LM3 world.
  • Hi Amit,
    >You mean the GPIO Trigger to the ADC
    ADCEMUX individual sequencer GPIO trigger, triggered perhaps by individual GPIO pin interrupts (best) or the entire port wide if need be. NVIC appears only passing 12 INTS per cycle in the load count trigger sample ready interrupts. Just today read NVIC section of data sheet refers that exact magic number (12) is by design.
  • Hi Amit,
    Have configured the SW for 3 GPIO discrete pins OR'd to (trigger external source) a single sequencer with 3 steps. We unwind each individual step sample end in the same interrupt handler. The SW configures each of the GPIO discrete pins to trigger a rising edge interrupt event to NVIC.

    The question is what to do about the GPIO discrete pin interrupt assignment in (startup_ccs.c)? The ADCEMUX EM0-EM4 register text mentions GPIO interrupt can be expected from the external source. We need to identify the rising edge of the GPIO input pin order to synchronize it with the ADC trigger rather than just presenting a level to trigger the ADC sample. Can the discrete interrupt vector assignment simply be ignored and still gain the advantage of rising edge interrupt detection to trigger the ADC?
  • Hello BP101,

    Yes, If the pin interrupt is not required but only a trigger it can be handled by selecting only rising edge for trigger generation and not setting the IM bit in the corresponding GPIO pin locations.

    Regards
    Amit
  • Hi Amit,

    So it seems only the interrupt source is set by configuring the interrupt pin type and the service handler IM entering it in startup_ccs.c? Never really connected the dots before yet knew we had to add the handler for the interrupt to vector.

    That said do we still have to clear the GPIO interrupt source each interrupt cycle, my thought is in the ADC interrupt handler?

    Thanks :)

  • Hello BP101,

    Can you share the GPIO Configuration code for the trigger?

    Regards
    Amit
  • Hi Amit,

    It seems plausible each of the OR'd GPIO pin interrupt trigger sources should be cleared in samples interrupt handler.

    MAP_GPIOPadConfigSet(GPIO_PORTQ0_AHB_BASE, GPIO_PIN_2, GPIO_STRENGTH_2MA, GPIO_PIN_TYPE_STD);
    MAP_GPIODirModeSet(GPIO_PORTQ0_AHB_BASE, GPIO_PIN_2, GPIO_DIR_MODE_IN);
    
    /* ADC trigger source edge event interrupt initiator */
    ROM_GPIOIntEnable(GPIO_PORTQ0_AHB_BASE, GPIO_INT_PIN_2);
    ROM_GPIOIntTypeSet(GPIO_PORTQ0_AHB_BASE, GPIO_PIN_2, GPIO_RISING_EDGE | GPIO_DISCRETE_INT);
    ROM_GPIOADCTriggerEnable(GPIO_PORTQ0_AHB_BASE, GPIO_PIN_2);
    ROM_IntEnable(INT_GPIOQ2);

  • Hello BP101

    If you remove the following 2 lines the ADC trigger does not work?

    ROM_GPIOIntEnable(GPIO_PORTQ0_AHB_BASE, GPIO_INT_PIN_2);
    ROM_IntEnable(INT_GPIOQ2);

    Regards
    Amit
  • Hi Amit,

    It seems to me if the interrupt is not enabled or simply removed the GPIO rising edge event would not trigger the ADC. The real question then, is the ADC external trigger source considered an NVIC or GPIO source event?

  • Hello BP101

    The Event Generation requires the event to be programmed. Once the event is generated then based on the GPIOIM, GPIOADCEV and GPIODMAEV register values the interrupt, ADC trigger and DMA trigger shall be generated respectively.

    Regards
    Amit
  • Hi Amit,

    It actually required the IM to be configured for the external trigger source (GPIO rising edge interrupt event) to even be asserted. It also required disabling the interrupt source which apparently stops NVIC from servicing the rising edge interrupt yet triggers the ADC. So it was not required to clear the interrupt source each cycle being it was disabled yet allows the rising edge event to assert each cycle.

    This now seems this new configuration is working beyond expectation. This has made for water cooler discussion; Can the PWM control block output pins in future MCU designs being used for an ADC trigger initiator? It seems this same scenario could be used for real time high side current monitoring as well.
  • Hello BP101

    Let me try the GPIO configuration as mentioned in the earlier post.

    Regards
    Amit
  • Hi Amit,

    Would like to test this same configuration on legacy LM3 being the INA282 shunt current monitor is so dang precise. After the low level ADC sample noise was removed by replacing Opamps doing current monitoring it was revealed PWM GEN0 triggered load count samples are not covering all the electrical angles. The problem seems that trapezoidal wave shape is complex, has good and bad attributes, some we want to monitor current and others we might want to ignore. 

    That sample behavior now restricted by comparator monitor at times catches random undesired current spikes tripping the PWM fault comparator. Seems an indication the pitfalls of single generator trigged ADC samples in a 3 phase 120 degree phase angle topology. Would like to prove that hypothesis on legacy LM3 before adopting to TM4C current monitor schema. The problem with LM3 uses GPIO pin B4 the only selection available in the ADCEMUX for all 4 sequencers.

    Another possibility perhaps TI engineers can check hypothesis 3 generator ADC triggers TM4C123 with BOOSTXL DRV8301 in the lab. The DRV8301 is shown mated to C2000 Piccolo F28027F yet is close to EK-TM4C1294XL booster pack 2 header pin layout but for only a few pins. DRV8301 might mate with the EK-TM4C123XL launch pad but couldn't say for sure. The point is wouldn't TI engineers also like to know for sure as I did?

     

  • Hi Amit,

    See how nice the current looks after SW changes sample data is filtered in sync to PWM triggers. Seems am on to something when the samples start to visually relay real time oscilloscope attributes. Imagine how digital current might appear if all 3 generators could trigger samples driving low side MOS and capturing/displaying each phases current events in real time.

    Results of 3 separate ADC samples of current triggered from PWM0 Gen0 shown below. Ideally the PWM single ADC triggers 3, one each generator yet can't. Unless later discussed posts below ADC samples are triggered remotely via GPIO monitor inputs on each PWM generator.

    Target current set below maximum peak so the duty cycle pulses are filtered:

  • This TI Webinar gives us a good example of why real time power management is most critical especially in grid tied inverters!

    training.ti.com/systems-made-simple-part-4-dsps-solar-inverters
  • BP101 said:
    Seems I am on to something here

    Would not that, "On to something here" be far better supported with the display of the more normal/expected, "Wider PWM" drive signals?      

    Are not those - rather narrow (power-limiting) - PWM pulse widths eroding the claim?   (i.e. setting the goal-posts (lower AND closer) may not be overly convincing!)

  • The post above spy each 80us current period derived in the aligned PWM pulse showing a high definition view of each FET inductive avalanche in a digital rendering. More important is the MOSFET current period has a highly defined amplitude due to the INA282 noise rejection, high precision and low drift amplifier at various temperatures.

    Lesson learned; We don't need to push the MOSFET over the cliff just to get a good energy release in the inductive current avalanche. Constraining current avalanche by integrating PWM duty cycle produces aspects that linear shunt voltage rise injected into SAR ADC can not replicate. When we sample that event is extremely important that event not skew from the real time event before it has been sampled in the ADC acquisition time.
  • Let's say, "All of that is true" (I'm unconvinced) would it not be far more impressive (and marketable) if you'd post such, "high definition view of each FET inductive avalanche" (huh?) at reasonable power levels - not "dialed down" to (almost) 500W (i.e. toy) level?   Does a motor - bolted down to your basement concrete - require such "securing" if we're driving ONLY @ LESS THAN ONE-TENTH of its capacity?   (i.e. you "claim" an Avalanche - yet curves reveal (at most) small Snowflake!)
     
    You know that firm/I are, "tech promoters" - those (rather pedestrian) curves/values generate little (i.e. no) excitement - can't you post a more meaningful (i.e. similar size/shape curves but @ 2KW (or greater) output?)

    That's marketable - that presented (thus far) not at all...

  • The point of INA282 in RDK was to gain a more accurate before and after DOE analysis. How do we prove the 20th century has a few things wrong about horse power now being defined and directly tied to Kilowatts. This latest DOE analysis proves that is not true at all especially of BLDC motors as they get more efficient at higher voltage. The US Department of Energy has lately pushed claims that HP coverts directly to KW in all motors and or engines.

     

  • BP101 said:
    The US Department of Energy has lately pushed claims that HP coverts directly to KW in all motors and or engines.

    That equivalence is true by definition. Both are measures of the physical property of power.

    This is quite different from brake horse power which is often used to rate engines.

    Robert

  • Unfortunately internet conversion calculators and various formula make no such distinction in classes of horse power in that definition.

    The DOE attempt to rate all motor as if the KW produced always has a direct relation to HP is 20th century bunk based on AC and not DC power creating simulated AC current.

    HP and KW remain distinctly different animals - not so easily to mix one with the other and expect any formula will produce the same outcome in all cases.

    Will the true horse power please stand up: If a generator typically requires 18 HP diesel engine to produce 12KW of 220VAC how can we say it takes the same electrical +/- HP based on the AC KW alone. Seemingly that would be a very bad mistake judging from the DOE results posted above. Referring to the DOE article CB1 posted about documenting analysis test results before and after.
  • BP101 said:
    Unfortunately internet conversion calculators and various formula make no such distinction in classes of horse power in that definition.

    That would be because there is no relation between brake horse power and kW. Brake horse power is largely a measure of motor inertia.

    BP101 said:
    The DOE attempt to rate all motor as if the KW produced always has a direct relation to HP is 20th century bunk based on AC and not DC power creating simulated AC current.

    HP and KW remain distinctly different animals - not so easily to mix one with the other and expect any formula will produce the same outcome in all cases.

    Wrong.

    BP101 said:
    Will the true horse power please stand up: If a generator typically requires 18 HP diesel engine to produce 12KW of 220VAC how can we say it takes the same electrical +/- HP based on the AC KW alone.

    I expect you will find both the engine and the generator get rather warm.

    Robert

  • The unspoken word (Torque) is missing in that improper conversion from KW to HP.

    KW don't convert in any way directly into Torque which is relative only to (Torque pounds * RPM / 5252 = HP). One might surmise heat energy (KW) released by producing Torque is partly equivalent to a small part of KW but not in an exact calculable amount. Only when we know one side of the equation can we truly know the other is even valid otherwise the formula is useless to predict required HP for the required KW output.

    Kilowatts are reactive energy resulting from producing torque in the presence counter EMF. Professors need to clarify the difference between LEZS law and counter EMF as reactive energy which they have yet to do.

    The plotted GUI examples above and many other independent scientist are proving that formula is not always correct in predicting the Required KW in the aspect of required Torque. How do we know it requires 18HP diesel to run a 12KW AC generator and otherwise a 24HP gasoline engine is relative mostly to Torque not so much KW.

    Seemingly predicting the torque relation to the required KW energy output becomes a better method in determining the wasted reactive heat Energy. The problem then becomes which way to go with current in order to achieve less destructive wasted KW and more efficient Torque. It seems in BLDC motors pushing current down and voltage up produces less destructive reactive KW energy and more efficient torque results. Thanks to the INA282 current shunt monitor for bringing out that aspect of current versus voltage. Form the basics, voltage is the electrical pressure behind current then seems to have a missing entry in the equation for an unknown amount of counter EMF reactive energy. Perhaps a Yokogawa power analyzer would shed some light in the absence of any real or proven science supporting the GUI plots above.

    Jim gives a good presentation on reactive energy which it seems he is describing torque. I for one appreciate what Jim has done to reveal the hidden inner truth of reactive energy.

    https://www.youtube.com/watch?v=HK3JOlY0V8Y&feature=player_embedded

     

  • BP101 said:
    The unspoken word (Torque) is missing in that improper conversion from KW to HP.

    Wrong

    BP101 said:
    KW don't convert in any way directly into Torque

    It does in exactly the same fashion as HP.

    This is basic (first year undergrad, and probably high school) physics.

    Robert

  • >It does in exactly the same fashion as HP.

    Perhaps post a conversion calculator link would be more believable of that challenge.

    In the context of counter counter EMF often spoken of as motor counter torque the conversion of HP direct to KW and the reverse is not proving true in our custom BLDC motor driven by a LM3S8971 MCU. We hope to have the TM4C1294 doing a faster sampling of the INA282 in very near future. Presently at times LM3S seemingly skips sample cycles in the ADC triggering from the PWM generator yet that doesn't fit such a drastic change in motor efficiency or believe me it would blow fuses or short out MOSFETS at the much higher DC voltage.

    The two GUI plots prove +150VDC is more efficient than +69VDC to produce the same HP or better in the very same BLDC motor. That in of its self challenges the very premise of KW to HP conversion may be flawed (in some cases). The INA282 is not measuring DC power supply current rather the current developed in the MOSFET duty cycle current avalanche cycle used to develop the same torque in both test cases. Interesting is the 2KW AC toroidal isolation transformer (Watts) are lower +150VDC loaded motor run than at the +69VDC loaded motor run. That seems to make the case that one is far better than the other.

    It wasn't until couple of years ago the DOE made the sudden change to rate small engines in KW versus HP but only in small gasoline and diesel engines. Example; a 24HP gasoline engine produces more KW of wasted heat energy than an a more efficient 18HP diesel @11KW 2600 RPM. Yet each engine (unequal HP) produces the necessary pound foot of torque to drive the same 12KW AC generator. We shouldn't simply nutshell that Generator output KW directly relates to engine HP required to produce the same KW output from the generator in both cases. That simply isn't true.
  • BP101 said:
    >It does in exactly the same fashion as HP.

    Perhaps post a conversion calculator link would be more believable of that challenge.

    Power (kW) = Torque (N.m) x Speed (RPM) / 9.5488

    From http://www.wentec.com/unipower/calculators/power_torque.asp (It does both SI and Imperial conversions).

     

    Or you could just read a high school physics textbook.

     

    Robert

  • That's a nice calculator, a bit more convincing but then again creates even more questions about the INA282 and LM3S8971 MCU test results. The calculator is not exactly correct in matching the KW to HP on my 12KW generator. In reality it requires a lot more HP to get 12KW from the generator than the calculator proves. For some unknown reason the V36 BLDC motor defies all present day formulas and calculators!

    The results above GUI plots of motor (TI INA282 current detection) has the same load conditions in each case. Seems to me in science we shouldn't accept the first test result as being remotely correct and simply disqualify the second because it defies power calculators or formulas.  

    That is not saying Robert you are wrong as several times you have done based on what you believe to be true in your mind. You argue in the scope of these test results around present day formulas yet the test results say they may be wrong. Perhaps these results have something to do with (F=MA) moving magnetic flux domains have velocity within a larger moving mass at specific flux (voltage) cancels out some of the effects of counter counter EMF in the phase coils. Far as I know the V36 BLDC motor is the first ever built by mankind (us) so there has never existed any such prior testing. BTW the Obama DOE turned down our unsolicited grant proposal to further the research on the V36 BLDC motor stating like technology already exists. Well then shouldn't electric cars now be getting 1000 miles distance between charging the battery?

    Keep in mind Einstein rewrote all text books in the 20th century when the entire science community defied his find that gravity bends photons around planets. It's no wonder man kind is still struggling with the Effects of counter EMF, HP and KW in the 21st century. These test results warrant a higher investigation level than we are capable to provide mankind with from my basement.

  • BP101 said:
    In reality it requires a lot more HP to get 12KW from the generator than the calculator proves.

    You're surprised by this? Seriously!!?

    BP101 said:
    DOE turned down our unsolicited grant proposal to further the research on the V36 BLDC motor stating like technology already exists. Well then shouldn't electric cars now be getting 1000 miles distance between charging the battery?

    The range limitations of electric vehicles (cars or otherwise) are not due to either motor or controller and have not been for at least 25 years. Anyone who thinks otherwise is doomed to disappointment.

    Robert

  • So it seems you agree we can't convert exactly a known output KW to the required HP to develop a given known KW rating. Adding the torque in the formula helps in that conversion calculator and makes for a good effort truer final answer. Had searched back awhile ago for similar calculator got stuck with the basic.

    Have to agree with battery range in part due to lack of serious battery voltages.

    >The range limitations of electric vehicles (cars or otherwise) are not due to either motor or controller and have not been for at least 25 years. Anyone who thinks otherwise is doomed to disappointment.

    Sorry to disagree - basic results are posted here for anyone with an open mind will see higher voltage has a direct effect in this custom BLDC motors efficiency. Combined to a rudimentary BEMF rotor position, hesitate to imagine what Piccolo C2000 FOC might do with it. Seems a bit of an opinion in claim progress should simply stop on BLDC designs which in the last 25 years until recently have not improved by much in efficiency or run at higher voltages for extended time. Otherwise the claim of range would much further along than 300Km.

    FEM analysis has become more accurate and NdFeB has helped efficiency. There is lots of room for improvement non of which many companies were awarded in kind grants that others of lessor impact received under the Obama run DOE. Most of those grantors are now bankrupt gives us a clue to what really went down. BTW the battery voltages mysteriously keep inching there way up from 97v-137v-173v perhaps they to see a similar pattern. Our BLDC motor could be easily made to run at 1200vdc in that scenario where expent heat in similar motors becomes is an issue with NdFeB magnets, not so much with Sm2Co17 which tolerate up to 350 Celsius prior to demagnetization. The point is to recover the reactive energy before it becomes expent as wasted heat not simply throw it away.

  • The EV drive controllers I was involved with over 30 years ago had measured efficiencies well over 90%. We had to resort to calorimetric techniques to measure it. Depending on construction and quality of the waveform fed to the motor they will be over 90%, certainly 80%. So there is just not room there for a range multiplier. Generally efficiencies go to either reducing heat or reducing the motor size.

    Range has been about the battery for a century or more. Replacing the old resistor controls with SCR based controls was a significant improvement, adding maybe 50 - 70% to the range and Mosfets added some more but we are well past the time that significant range improvements are possible by substituting a different motor or control technology.

    Battery voltage is pretty arbitrary, you can get any voltage you want by stacking cells. Higher voltages actually have slightly lower capacity because of the additional required cell packaging. What matters are volumetric energy density, gravimetric energy density and monetary energy density. And there appears to be good electrochemical reasons for thinking we are approaching the limits on the first two.

    It's been updated battery chemistry that has increased electric automobile range not motors and controllers. Other EVs have not been affected as much as they are more cost sensitive and the range improvement is of less practical significance.

    Robert
  • Perhaps check out the Civic Hybrid which replaced an earlier DC motor with and advanced 2" wide ring magnet motor between the engine and transmission. That of it self increased motor efficiency extending drive range at the same time. The controller PWM dynamics have largely been responsible for gains in battery range from developing better GTO modulation algorithms and current management schemes. One method removes wasted heat energy in liquid stator cooling that keeps copper wire resistance from rising in the motor otherwise driving down efficiency without auxiliary cooling. There is a lot more room for advancing DC motor technology and stator cooling schemes far from where they now stand.

    Yet another Tesla soon to hit the market claims 350Km, not achieved from advances in battery alone comes at a hefty sticker $35k.
  • Regarding battery improvements see

    www.intechopen.com/.../energy-storage-battery-materials-and-architectures-at-the-nanoscale

    Check figure 4.

    The monetary energy density is also improving apace.

    I believe you are referring to the economy Tesla, their business model is predicated on steady, even dramatic cost improvements in the battery. They are going so far as to try to push that improvement along themselves. And Tesla's range is due primarily to the large battery packs they use, much larger than their shorter ranged cousins.

    As for the hybrid change, there is a dictum often given to new SF authors, you cannot change just one thing. That applies to engineering as well. Note the multiple changes, new motor with new (almost certainly more efficient gearing), less mounting required (and the transmission housing may strengthen it so less vehicle weight), they may have reduced the flywheel and used the motor to compensate (less weight again), it's a newer model there's a good chance the battery pack was improved and finally they may have increased the allowable depth of discharge range. There's probably many more but you get the idea.

    Robert