Practical AC Motor Controller Design Solutions of High Current Control for 5～15kW Particular Electric Vehicles

摘要

In this paper, an AC motor controller with simple interfaces, functions, and low cost is presented for 5kW-15kW particular electric vehicles. Generally, particular vehicles mean usage for short distance and specified driving zone, such as golf cars, lifting or carrying cargo vehicles and small shuttle bus, etc. All of these vehicles possess characteristics of large torque at low speed, fixed driving route and operating range. Furthermore, complicated functions are unnecessary. For above requirements, this research is to develop a universal motor controller, which can perform torque control of both permanent magnet synchronous motor (PMSM) and induction motor (IM) through common interfaces for different vehicles. Related controller hardware and software design are illustrated in this paper. There are five parts in this paper as follows. (1) The hardware design includes a construction of motor drive, functional and circuit design of control stage, pin diagram of motor drive and schematic design of power stage. Note that the developed controller can drive different power motors by replacing different power stages, which consist of several parallel-MOSFETs. Thus, low cost can be fulfilled. (2) In the software design part, this research includes vehicle control logic, TPS detection, pre-charge function, thermal protection, speed and rotor angle estimation, and current control. (3) In experiments, torque-speed map and efficiency map for different driving motors are implemented to provide a reference of vehicle calibration. (4) Environmental tests including EMC/IP/Temperature/Vibration guarantee stability and reliability of the motor controller. Finally, (5) a carrying cargo (1～2 ton) vehicle in a specified market is applied to verify the controller durability.