Designing an electric vehicle motor controller using the InstaSPIN FOC platform

Austin Bartz

Other Parts Discussed in Thread: LAUNCHXL-F28027, LAUNCHXL-F28069M

Hi all,

I'm just starting to design a motor controller for my school's SAE Formula Hybrid Vehicle (Milwaukee School of Engineering). Unfortunately I'm the only EE on the team, (everyone else is an ME), so this is probably going to take a while, but that's why I started this over the summer.

For those not familiar, SAE Formula Hybrid is a collegiate competition where universities from around the world build a hybrid Formula 1 style race car and compete. http://www.formula-hybrid.org/

So, back to the details of the project. The motor we plan on using is an EMRAX 268MV running at 300VDC. It's basically a glorified BLDC R/C out-runner. So I feel that it'd be doable to drive it using the InstaSPIN FOC platform. http://www.enstroj.si/Electric-products/emrax-268.html

For the system I would use the "LAUNCHXL-F28027" as the controller for my own power stage for the EMRAX Motor. If this will all work as planned.

-- EDIT --

I should probably include a specific question...

So, do you think that this sounds doable, or is controlling a 100kW motor with the InstaSpin FOC sensorless system not possible/ideal?

Thanks!

over 10 years ago

0 Clancy Soehren over 10 years ago

TI__Mastermind 23810 points

It's great that you are getting started early! Do you have a specific question? I moved this thread to the InstaSpin forums, so hopefully you can get a discussion started here.

0 Jorge Zambada over 10 years ago

TI__Expert 5180 points

For a 300VDC motor the only kit that we have is this one: www.ti.com/.../tmdshvmtrinspin

That kit comes with a control card that has a microcontroller with the FAST observer libraries in ROM.

-Jorge

0 Austin Bartz over 10 years ago in reply to Clancy Soehren

Prodigy 90 points

I wasn't sure which forums would've been better, given that it's for an automotive application, so thank you for moving it to the correct forum!

As for a specific question I guess I just want to see if this is even a good idea. I know the InstaSpin FOC works well on smaller motors, but I don't know if it'll work for something in the 100kW range and that if I could even get away with a sensorless setup.

Thanks!

0 Austin Bartz over 10 years ago in reply to Jorge Zambada

Prodigy 90 points

I came across that kit, but unfortunately it's far too expensive for me to buy on my own for prototyping. Once I get a small scale version working with the kit I bought and if I feel like the InstaSpin FOC system will work for a 100kW motor, then I will look into getting the funds to buy the HV kit.

Thanks!

0 ChrisClearman over 10 years ago in reply to Austin Bartz

TI__Guru** 119670 points

Yes, it will work on 100 kW motors. Check out what this guy is doing with LAUNCHXL-F28069M and InstaSPIN:
hackaday.io/.../6307-hacking-powerful-ev-drivetrains

Is this a synchronous PM machine or asynchronous induction? For asynchronous the motor ID portion is not as robust...a bigger challenge to get good parameters, but if you are designing the machine yourself you likely have the necessary parameters to calculate.

0 Michal Elias45 over 10 years ago in reply to ChrisClearman

Prodigy 130 points

That Tesla motor is mine :)

Just be careful when working with big motors. You will be having a debugger connected to system that works with very high power and voltage - and most likely will be able to deliver a lot of current (in case of batteries). The library will allow you to enter almost anything in the user.h - make sure you properly test everything on a small motor before.. Even then the ID part will be tricky.

0 ChrisClearman over 10 years ago in reply to Michal Elias45

TI__Guru** 119670 points

very cool, Michal!

0 Austin Bartz over 10 years ago in reply to ChrisClearman

Prodigy 90 points

That's good to hear!

The EMRAX motors are listed as being "brushless synchronous 3 phase AC motors", so I think they shouldn't be an issue to get get ID'd with the system.

Thanks!

0 Austin Bartz over 10 years ago in reply to Michal Elias45

Prodigy 90 points

I just looked at your Hackaday page and the video. I must say, that is really cool! I actually was wanting to look at how Tesla did their motor control and try to use their techniques when building my system.

Thanks for the tips!

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Designing an electric vehicle motor controller using the InstaSPIN FOC platform