Assignment

Motor Controller Design

 • When a wire carrying electric current is placed in a magnetic field, a magnetic
force acting on the wire is produced.

• The force is perpendicular to the wire and the magnetic field.

• The magnetic force is proportional to the wire length, magnitude of the electric
current, and the density of the magnetic field

Magnetic Force 𝐹 = 𝐵𝐼𝐿

Torque 𝑇 = 𝐵𝐼𝐿 𝐶𝑜𝑠𝛼
𝛼 − angle between the coil plane and magnetic field F= Force, B = magnetic flux
density, I = current
Flux ControlArmature & Rheostat Control

SPEED CONTROL:

ADVANTAGES DISADVANTAGES

• High Torque • High Maintenance cost

• Simple Control • Poor Efficiency
• Low Cost
BLDC Motor Speed Control

Brushed DC Commutation

● The windings in the armature are switched to the DC power by the brushes and
armature

● Each winding sees a positive voltage, then a disconnect, then a negative voltage

● The field produced in the armature interacts with the stationary magnet,
producing torque and rotation

DC Motor Bridge

● The DC motor needs four transistors to operate the DC motor

● The combination of transistor is called an H-Bridge, due to the obvious shape

● Transistors are switched diagonally to allow DC current to flow in the motor in

either direction

● The transistors can be Pulse Width Modulated to reduce the average voltage at the
motor.
Three-Phase Bridge to Drive BLDC Motor

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 1 STEP 2 STEP 3

Six-step Commutation

● The Brushless DC motor is really a DC motor constructed inside-out, but without the
Brushes and Commutators

● The mechanical switches are replaced with transistors

● The windings are moved from the armature, to the stator

● The magnet is moved from the outside to become the rotor

3-Phase PWM:

We can divide up the phase data into individual transistor gate signals
U

VP
 Battery For EV Application

Types of EV Battery

● Lithium-ion

● Lithium Phosphate

● Nickel-metal hydride batteries

● Lead-acid batteries

●
Battery Parameters

Battery SoC: The fraction of the total energy or battery capacity that has been used over the
total available from the battery
Shows the remaining capacity of the battery while in use

Battery Calculations

Step #1 Current Consumption by Motor P = V x I

I = 10KW/72V

Current required to run full load by the Motor - 139 Amps

Step #2 Watt-Hour Calculation Assume Running Time 1
Hour
P = 10000 x 1 Watt -Hour
Step #3 Ampere Hour Calculation

The Source must have 20-30% more than the required energy

Assume : 20%

Watt-Hour = 10000 x 1.2 = 12000

Ampere Hour = Watt-Hour /Battery Terminal Voltage

= 12000/72

= 166.67Ah
Battery Rating 72V, 166.67Ah
Current required to run full load by the Motor - 139 Amps
Step #2 Watt-Hour Calculation Assume Running Time 1
Hour
P = 10000 x 1 Watt -Hour
Step #3 Ampere Hour Calculation

The Source must have 20-30% more than the required energy

Assume : 20%

Watt-Hour = 10000 x 1.2 = 12000

Ampere Hour = Watt-Hour /Battery Terminal Voltage

= 12000/72

= 166.67Ah
Battery Rating 72V, 166.67Ah

SoC Estimation
State of charge (SOC) is a relative measure of the amount of energy stored in a battery,
defined as the ratio between the amount of charge extractable from the cell at a specific point
in time and the total capacity

Methods to Estimate SoC

● Coulomb Counting

● Kalman Filter

● Extended Kalman Filter

 Simscape Introduction

● Modeling and simulating multidomain physical systems

● Elements for various physical domains

● unit manager, data logging etc

Protocols for EVs

PROTOCOL: It’s an agreement about how to do something

Communication:

● Fault tolerance

● Determinism

● Bandwidth

● Flexibility

● Security

Controller Design

● Motor Type: PMDC Motor

● Operation: 4 Quadrant

● Motor Speed 0-100rpm

● Vehicle Speed: 0-20/25 kmph

● Break: Regenerative Brake

● Controller: Arduino Mega

 Power Supply Requirements

● Motor Power Supply (Battery: 24V)

● Gate Driver Power Supply (15V DC)

● Arduino Power Supply (5 V DC)

 SCOPE OF ELECTRIC VEHICLE

Automakers from all around the world are sighting a keen eye on Indian markets. With world’s
largest electric vehicle manufacturer, Tesla coming into to the Indian electric automotive
spectrum, it is not futile to say that India got a new lease for becoming the future hub for
electric vehicles.
However, the pandemic has slowed the growth speed of India by leaps and bounds.
As electric vehicle manufacturing is becoming popular every day, its market share is also
expected to rise greatly. India's GDP is expected to grow by an amazing 25% by 2022. The
best part is that, apart from reducing environmental pollution, EVs can lower oil import by
about $60 Billion by 2030.
 fig . Simulink model of Speed control of a DC motor using BJT H-Bridge

Working of H-bridge model:

 Here H-bridge DC chopper circuit is designed to control the speed of the motor.
 IGBT acts as BJT in power switching devices.
 Four IGBT switches are used for inverting the DC voltage 0 to 240 v supply.The current flows from
collector(C) to emitter(E).
 The gate are controlled by the pulses(0 and 1) according to the armature voltge of motor given by pulse
generator.
  This image shoes the voltage value given from initial to final during the step time.According to the pulses
on and off the voltage supplied to the IGBT's.
 Here four switches are used Q1,Q2,Q3,Q4. Pulses P1,P2,P3,P4 are conected with corresponding
switches.
 In first state, Q1 and Q4 are closed by giving 1V to IGBT'S,current from battery passes through Q1 and
Q4.Diode D2,D3 are used as free wheeling diode in this state.In this case Forward motoring and forward
breaking are held.
 In Second state,Q2 and Q3 are closed by giving 1V to IGBT's,current from battery passes through Q2 and
Q3.Diode D1,D4 are used as free wheeling diode in this stateIn this case reverse motoring and reverse
breaking are held.The current direction change its direction in this state.
 Both the states are occuring in 0.5 seconds in their sample time.Thus DC supply converted and feeded to
the armature of the motor.
 Here free wheeling diodes are used as a safety purpose of this inverter circuit as when the flow of current
on low values protects the circuit and machine by feed backing the current or in high voltage
fluctuvations voltage get splited as protection to the motor and circuit components.
 In motor operation, armature terminals are connected with a 240V along the inverter circuit and field
windings are connected with 300 V DC suppy to act as a electro magnet for the motor.
 The load torque is given as mechanical input to the motor for its referance.
 Thus through this magnetic fields generated, variable current carring conductors in rotor armature
produces forces according to fleming left hand rule principle. Thus the motor starts to rotate.
 Here run this demo model and study the results from scopes.

Result:
From the result scope we are getting,

Speed of motor:

 Initially increases to 0 to nearly 900 rpm upto 0.5 secs(Forward motoring action takes place).
 Then speed reduces to 0 rpm(Forward dynamic breaking action takes place).
 Then speed increases from 0 to -900 rpm at upto 1 sec( Reverse motoring action takes place).
 Then reverse dynasmic breaking occurs(Not shown in scope).

Load torque of motor:

 Initially torque increase from 0 to 0.5 secs in forward motoring action.

 Then torque reduces to 0 Nm in forward dynamic breaking mode.
 Then torque increases in reverse direction in reverse motoring action upto 1 sec.
 Again torque reduce to zero.(Not shown in scope).

B) Armature current shoot up in motor.

Here the initial current shoot up is due to sudden increase in voltage which inurns regulated by duty cycle.In this
case motor driven in 75% of duty cycle.(i.e) 0.75*240= 180 V.

We can change the duty cycle to 50%(120 V) and seen the results as,
Sudden shoot up canceled in starting condition but slight shootup after 0.5 sec in reverse motoring
condition.

Again changing duty cycle to say 35%,we get the result as,

The shoot up of current get dimlished on both the ends.

Conclusion:

Thus to reduce the shootup armature currents we have to change the duty cycle gradually from 0 to 100%,that
inturns increases voltage gradually and speed also changes accordingly.